Bone fixation assembly

ABSTRACT

The present invention is directed an anchor assembly for use in spinal fixation to interconnect a longitudinal spinal rod with a patient&#39;s vertebra. The anchor assembly preferably includes a bone anchor, a body with a rod-receiving channel, an insert member (preferably a bushing), and a locking cap with a saddle. The anchor assembly preferably enables in-situ assembly where the bone anchor may be secured to the patient&#39;s vertebra prior to being received within the body of the bone anchor assembly. Accordingly, the anchor assembly enables a surgeon to implant the bone anchor without the body to maximize visibility and access around the anchoring site. Once the bone anchor has been secured to the patient&#39;s vertebra, the body may be snapped onto the bone anchor and a spinal rod may be inserted into the rod-receiving channel.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is a continuation application of U.S. patentapplication Ser. No. 15/835,524, filed Dec. 8, 2017, which is acontinuation application of U.S. patent application Ser. No. 15/046,977,filed Feb. 18, 2016, which is a divisional application of U.S. patentapplication Ser. No. 13/061,773, filed Mar. 2, 2011, which is a U.S.National Stage Application of PCT Application No. US2009/056100, filedSep. 4, 2009, which in turn claims priority to U.S. Provisional PatentApplication No. 61/094,622, filed Sep. 5, 2008, the contents of all ofwhich are hereby incorporated by reference as if set forth in theirentirety herein.

BACKGROUND OF THE INVENTION

It is often necessary due to various spinal disorders to surgicallycorrect and stabilize spinal curvatures, or to facilitate spinal fusion.Numerous systems for treating spinal disorders have been developed.

One method involves a bone fixation system including a pair of elongatedmembers, typically spinal rods, longitudinally placed on the posteriorspine on either or both sides of the spinous processes of the vertebralcolumn. Each rod is attached to various vertebrae along the length ofthe spine by way of bone fixation or bone anchor assemblies, e.g.pedicle screws. The body of the pedicle screw often has a rod-receivingchannel and receives a locking cap to secure the spinal rod to thepedicle screw.

To facilitate insertion of the spinal rod into the rod-receivingchannels of the pedicle screws, pedicle screws have been developedwherein the body is separate from and pivotable with respect to the boneanchor (commonly known as polyaxial pedicle screws).

It is desirable to develop a bone fixation system and assemblies thatare simple for a surgeon to use.

SUMMARY OF THE INVENTION

The present invention relates generally to orthopedics. Morespecifically, the present invention relates to a bone fixation system(also referred to as a bone anchor system) including a bone fixationassembly (also referred to as a bone anchor assembly) having a spinalrod-receiving channel and an associated method for implanting the bonefixation system and bone fixation assembly.

The present invention is directed to a bone anchor assembly for use in aspinal fixation procedure that connects a support member (e.g., a spinalrod) to a vertebra. The anchor assembly preferably includes a boneanchor having an enlarged head portion (e.g., a bone screw), an insertmember (e.g., a bushing), a body having a bore for receiving the insertmember and a rod receiving channel, and a locking cap engagable with thebody and preferably having a saddle for receiving the spinal rod. Thebone anchor assembly preferably enables in-situ assembly. That is, theanchor assembly is preferably configured so that in use, the bone anchormay be secured to the patient's vertebra prior to being connected to thebody. Accordingly, the anchor assembly preferably enables a surgeon toimplant the bone anchor without the body and bushing to maximizevisibility and access around the anchoring site. Once the bone anchorhas been secured to the patient's vertebra, the body can “pop-on” to thebone anchor.

In one preferred embodiment, the anchor assembly includes bone anchormovable with respect to a body subassembly prior to fixing the positionof the spinal support member to the body subassembly. The bodysubassembly is preferably sized and configured to snap onto the head ofthe bone anchor and may include an insert member (e.g., a bushing), andreceives a locking cap preferably with a saddle. The bone anchorpreferably includes an enlarged head portion. The head portionpreferably includes a first tool interface for engaging a first surgicalinstrument operatively associated with the bone anchor. The bodypreferably includes a longitudinal axis, an interior wall, an upper endwith an upper opening, a lower end with a lower opening, a boreextending between the upper opening and the lower opening, and arod-receiving channel. The rod-receiving channel is preferablyconfigured and arranged to receive a spinal rod.

The bushing preferably includes an upper, rod-facing portion with anupper end, and a lower portion that captures and at least partiallysurrounds the head portion of the bone anchor. The lower portion of thebushing includes at least one, preferably a plurality of, slot(s)extending from the lower end, the slots preferably defining a pluralityof flexible arms, wherein each of the flexible arms have an outersurface. In the case of a multi-piece bushing, the slots in the lowerportion may extend either from the lower end with optionally one slotextending all the way to the upper end of said lower portion, oralternatively the slots extending from both the lower end and the upperend of the lower portion with optionally one slot extending all the wayfrom the upper to the lower end. The bushing is preferably movablypositionable within the bore of the body.

The locking cap preferably includes a saddle and a locking means orlocking assembly. The saddle has a plurality of saddle arms defining asaddle rod-receiving channel, and configured and arranged to be receivedwithin the bore of the body to retain the spinal rod. The locking meansor locking assembly may include either a locking element or assemblythat simultaneously locks the bushing and the spinal rod, or a lockingelement or assembly to lock the bushing separately from the rod, wherethe element or assembly locking the bushing is operatively associatedwith the saddle. The locking element or assembly locking the bushing ispreferably movably engagable with the body from an unlocked position toa locked position, wherein movement of the locking element or lockingassembly from the unlocked position to the locked position urges thesaddle, which in turn urges the bushing and the flexible bushing armsagainst the lower portion of the body to secure and fix the position ofthe bone anchor relative to the body. In the case of simultaneouslocking of the bushing and rod, the locking element or assembly urgesthe saddle against the rod, which in turn urges the bushing into alocked position. In the case of separate locking of the bushing and therod, the locking element or locking assembly which locks the bushingpreferably urges the saddle against the upper end of the bushing, whichin turn urges the bushing into the locking position. The locking elementto separately lock the rod with respect to the body is preferablyconnected to and received in the element that connects to the body (e.g.threaded ring), or is connected to and received in the saddle. Thelocking element to separately lock the rod may include a one-piece setscrew or a two-piece set screw with a saddle attached to the lower endof the set screw, or other configurations.

In another preferred embodiment the bone anchor assembly for use with aspinal rod for stabilizing bones or bone fragments is provided whichincludes a bone anchor, a body, an insert member receivable in the body,and a locking cap assembly. The bone anchor may have an enlarged,curvate head portion, and may connect to the bone or other substrateusing threads, hooks, clamps, stakes, tacks, pins, spikes or othermeans.

The body preferably has a longitudinal axis, an exterior sidewall, aninterior wall, an upper end with an upper opening, a lower end with alower opening, a bore having an interior wall, and a rod-receivingchannel. The bore of the body preferably extends substantially betweenthe upper opening and the lower opening and the rod-receiving channel ispreferably configured and arranged to receive the spinal rod. In oneembodiment, often referred to as a side-loading bone anchor assembly,the rod-receiving channel extends into the bore of the body from theexterior side wall of the body, and in another embodiment, oftenreferred to as a top-loading bone anchor assembly, the rod-receivingchannel extends downward from the upper end in the direction of thelongitudinal axis and communicates with the upper opening.

The insert member in one embodiment is preferably a bushing. The bushingpreferably has a first end, a second end, a lower opening, an interiorcavity and at least one slot extending from the second end, the slotpermitting the bushing to be expandable and collapsible. The bushingfurther has an outer surface and is movably positionable within the boreof the body. The outer surface of the bushing preferably has at least aportion that is frusto-spherical in shape. The outer surface of thebushing may further have at least one cylindrical zone where the surfacein the cylindrical zone has a substantially constant diameter in itsundeflected state, and wherein the lower end of the body has a chamberhaving a substantially cylindrical surface where the diameter issubstantially constant, wherein the bushing is positionable so that theat least one cylindrical zone is oppositely facing the cylindricalsurface of the body to inhibit the bushing from angulating in the body.

The bushing may be a single piece element or a multi-piece element. Inthe multi-piece bushing embodiment, the bushing may have a lower insertmember for receiving the head portion of the bone anchor, and an uppersleeve member. The lower insert member preferably has an outer surfaceat least a portion of which is frusto-spherical and further has at leastone slot and is expandable and compressible. The sleeve memberpreferably is interconnected to the lower insert member, the sleevemember preferably having a rod-receiving channel.

The locking cap assembly preferably includes a saddle and a lockingelement, the saddle having at least one saddle arm defining a rodreceiving channel, and configured and arranged to be received within thebore of the body to retain the spinal rod, wherein the saddle isoperatively associated with the locking element and the bushing, thelocking element being engagable with the body and movable from anunlocked position to a locked position. Movement of the locking elementfrom the unlocked position to the locked position when the spinal rod isreceived in the rod-receiving channel applies pressure to the spinal rodto secure or lock the position of the spinal rod with respect to thebody. The bone anchor preferably is poly-axially rotatable with respectto the body when the locking cap assembly is in the unlocked position.

The body and insert member may incorporate one or more features toassist in the operation and assembly of the bone anchor assembly. In onepreferred embodiment, the insert member preferably may further includeat least one wing extending from an outer surface of the insert memberand the body may further include at least one wing projection extendinglongitudinally on the interior wall in the body bore and a first stopdisposed in the bore above at least a portion of the at least one wingprojection. The first stop preferably is configured and arranged tocontact the at least one wing to restrict the upward movement of theinsert member within the bore of the body, and the at least one wingprojection preferably is configured and arranged to prevent the insertmember from rotating in selected areas of the bore of the body. The boreof the body may further have a first zone and a second zone, the firstzone including both the first stop and the at least one wing projectionsuch that the insert member is not permitted to rotate within the firstzone. The second zone may be located below the first zone and the insertmember is permitted to expand and rotate in the second zone.

The bore of the body may further include an enlarged chamber whichpermits the arms of the insert member to expand in order to receive thehead portion of the bone anchor when it is inserted through the lowerend opening of the body. The first stop may be configured to prevent theinsert member from extending up the body bore when the bone anchor isinserted into the body so that the arms of the insert member remain inthe enlarged portion of the body bore, and wherein the at least one wingis located in the first zone during insertion of the head portion intothe cavity of the insert member and the expandable portion of the insertmember is located in the second zone. The body preferably may furtherinclude a second stop disposed in the first zone below the first stop,wherein the second stop is constructed and arranged to restrict themovement of the insert member within the body by interfering with the atleast one wing.

In yet a further embodiment, the insert member may be a bushing thatpreferably includes a plurality of slots extending from the second end,the slots defining a plurality of flexible arms, wherein the arms havean outer surface at least a portion of which is frusto-spherical. Thebushing may further include at least a first wing and at least a secondwing on the outer surface of the bushing, the first wing having a widerwidth than the second wing and preferably extending outward from theouter surface of the bushing a smaller distance than the second wing.The body bore preferably has a chamber in the lower end including aninterference zone and a rotational zone, the interference zone having atleast two wing projections extending longitudinally and at least twofirst stops positioned above at least a portion of the wing projectionsand forming a first channel and a second channel, the first channelbeing of larger width than the second channel. The bushing first wingspreferably can extend down the first channel without interference whilethe bushing second wings cannot extend move within the first channelwithout abutting at least one of the first stops.

The locking cap assembly may take several configurations. In someembodiments of the locking cap assembly the bone anchor and spinal rodmay be separately locked where as in other embodiments the bone anchorand spinal rod may be simultaneously locked. In one embodiment whichpermits separate locking of the spinal rod and bone anchor, the lockingcap assembly includes a locking ring element, a saddle and a setscrewelement. The locking ring preferably is engagable with the body andoperatively associated with the saddle. The locking ring elementpreferably is movable from a ring unlocked position to a ring lockedposition, wherein movement of the locking ring element from the ringunlocked position to the ring locked position causes the saddle to movedownward within the body, which in turn moves the bushing downward inthe body, causing the bushing to contact the interior wall of the boreof the body causing the bushing to collapse around and fix the positionof the bone anchor with respect to the body. The set screw element maybe engagable with the locking ring element and movable from a screwunlocked position to a screw locked position, wherein movement of theset screw element from the screw unlocked position to the screw lockedposition when the spinal rod is received in the rod receiving channelfixes the position of the spinal rod with respect to the body.

In a different embodiment which permits separate locking of the boneanchor and the spinal rod, the locking cap assembly may also includelocking ring element engagable with the body and operatively associatedwith the saddle, and a setscrew element. The locking ring elementpreferably is movable from a ring unlocked position to a ring lockedposition, wherein movement of the locking ring element from the ringunlocked position to the ring locked position when the bone anchor isreceived within the body fixes the bone anchor with respect to the body.The set screw element preferably is engagable with the saddle andmovable from a screw unlocked position to a screw locked position,wherein movement of the set screw element from the screw unlockedpositioned to the screw locked position when the spinal rod is receivedin the rod receiving channel fixes the position of the spinal rod withrespect to the body.

The bone anchor assembly may incorporate features in the saddle and bodyto assist in its operation and manufacture. In one embodiment, the bodyincludes a lower body recess formed in the bore at the lower end, and atleast one saddle arm is sized and dimensioned to extend past the spinalrod such that the distal end of the saddle arm is receivable in thelower body recess and contacts the bushing when the locking ring isengaged with the body. The saddle may also be configured and sized andthe bore in the body may be configured and sized such that the at leastone saddle arm is form-fitted within the body when placed into the boreof the body. The at least one saddle arm may have at least one sidesurface perpendicular to at least one back surface, and the bore of thebody may have cooperating perpendicular surfaces, wherein the at leastone saddle arm is close-fitted within the bore of the body such that anyrotation or twisting deflection of the body is transferred to the saddlearm.

One of the saddle arms may also include an oblique bushing interfacesurface having an inclined surface at its distal end, and the bushinghas an oblique saddle interface surface having an inclined surface,wherein the inclined surface of the bushing is configured and arrangedto contact the inclined surface of the saddle when the locking elementis in the locked position. One of the saddle arms may include aperpendicular bushing interface surface having a surface at its distalend that is perpendicular to its side surface, and the bushing may havea perpendicular saddle interface surface having a flat planar surface,and the perpendicular end surface of the bushing preferably isconfigured and arranged to contact the planar surface of the saddle whenthe locking element is in the locked position.

In one embodiment, the body may further include a recess formed on theinterior wall in the bore and extending in the direction of thelongitudinal axis from the upper end towards the lower end, and thesaddle may further include a body engagement element, the bodyengagement element extending outward from the saddle and configured andarranged to engage the recess. The body may further include at least oneexternal recess in the exterior side wall proximate the rod receivingchannel and the saddle includes at least one wing extending outward fromthe saddle so that the at least one wing is configured and arranged toengage the external recess of the body.

In another preferred embodiment the anchor assembly includes amonorotational bone anchor, a body, a fastener element, and a lockingcap. The bone anchor includes a bone anchor upper portion and a boneanchor lower portion. The bone anchor upper portion includes a headportion and at least one head engagement element, wherein the headportion may include a first tool interface for engaging a first surgicalinstrument. The body includes a longitudinal axis, an upper end with anupper opening, a lower end with a lower opening, a bore extendingsubstantially between the upper opening and the lower opening, a rodreceiving channel constructed and arranged to receive a spinal rod, andat least one body engagement element disposed in the bore proximate thelower end. The fastener element, which may be a “C-clip”, spring clip,bushing, or any other retaining element constructed and arranged to beengagable with the at least one head engagement element to secure thebone anchor to the body, preferably as the body is attached to the boneanchor after insertion of the bone anchor into bone by inserting thehead of the bone anchor up through lower opening in the body. Thelocking cap includes a saddle and a locking element. The saddle has aplurality of saddle arms defining a saddle rod-receiving channel and isconstructed and arranged to be received within the bore of the body toretain the spinal rod within the body. The saddle is also operativelyassociated with the locking element, which is engagable with the body,wherein the locking element is movable from an unlocked position to alocked position. The movement of the locking element from the unlockedposition to the locked position when the spinal rod is received in therod-receiving channel secures the spinal rod with respect to the body.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

The foregoing summary, as well as the following detailed description ofpreferred embodiments of the invention, will be better understood whenread in conjunction with the appended drawings. The preferredembodiments of a bone anchor system including a bone anchor assembly areshown in the drawings for the purposes of illustration. It should beunderstood, however, that the application is not limited to the precisearrangements, structures, features, embodiments, instrumentalities, andmethods shown and described, and the arrangements, structures, features,embodiments, instrumentalities, and methods shown and described may beused singularly or in combination with other arrangements, structures,features, embodiments, instrumentalities, and methods. In the drawings:

FIG. 1 illustrates a side perspective view of a first embodiment of abone anchor assembly configured with a side-loading, rod-receivingchannel, in accordance with the present invention;

FIG. 1A illustrates a side cross-sectional view of the anchor assemblyof FIG. 1;

FIG. 2 illustrates a side perspective view of a second embodiment of ananchor assembly configured with a top-loading, rod-receiving channel, inaccordance with the present invention;

FIG. 2A illustrates a side cross-sectional view of the anchor assemblyof FIG. 2;

FIG. 3 illustrates a perspective view of a bone anchor system having afirst anchor assembly and a second anchor assembly implanted into firstand second vertebra with a spinal rod spanning the two vertebra;

FIG. 4 illustrates a side cross-sectional view of the body element ofFIG. 1;

FIG. 4A illustrates a top view of the body element of FIG. 4;

FIG. 4B illustrates a side cross-sectional view of the lower portion ofthe body element of FIG. 4 along line 4B-4B;

FIGS. 4C-D illustrate magnified, side cross-sectional views of the lowerportion of the body element of the anchor assembly of FIG. 4 withfeatures removed for simplification;

FIGS. 4E-F illustrate magnified, side cross-sectional views of analternate embodiment of the lower portion of the body element of theanchor assembly of FIG. 4 with features removed for simplification;

FIG. 5 illustrates a cross-sectional perspective view of a analternative preferred embodiment of the bushing element captured withina modified body element of FIG. 1A;

FIG. 5A illustrates a side cross-sectional view of the bushing elementcaptured within the body element of FIG. 5 and a three-piece lockingcap;

FIG. 6 illustrates a side cross-sectional view of the bushing element ofFIG. 5;

FIG. 6A illustrates a side view of the bushing element of FIG. 6;

FIG. 6B illustrates a top view of the bushing element of FIG. 6;

FIG. 7 illustrates a side cross-sectional view of the bushing element ofFIG. 1A;

FIG. 7A illustrates a side view of the bushing element of FIG. 7;

FIG. 8 illustrates a side cross-sectional view of the bone anchorassembly of FIG. 1A with the bushing element in an unlocked or loadingposition;

FIG. 9 illustrates a top view of the body and bushing subassembly ofFIG. 5;

FIG. 10 illustrates a perspective view of a three-piece locking capshown in FIG. 1A;

FIG. 11 illustrates a perspective view of the saddle element of thelocking cap of FIG. 10;

FIG. 12 illustrates a perspective view of a threaded ring element inaccordance with the present invention;

FIG. 12A illustrates a perspective view of an alternative embodiment ofa threaded ring element in accordance with the present invention;

FIG. 13 illustrates a perspective view of a set screw element inaccordance with the present invention;

FIG. 14 illustrates a top cross-sectional view of a saddle form-fittedin the body element in accordance with a preferred embodiment of thebone anchor assembly of the present invention;

FIG. 15 illustrates a top cross-sectional view of an alternative saddleform-fitted in the body element in accordance with a preferredembodiment of the bone anchor assembly of the present invention;

FIG. 16 illustrates a cross-sectional view of a third preferredembodiment of an anchor assembly in a locked state in accordance withthe present invention;

FIG. 16A illustrates a magnified view of a portion of the bone anchorassembly of FIG. 16;

FIG. 17 illustrates a perspective view of a fourth preferred embodimentof the bone anchor assembly of the present invention;

FIG. 18 illustrates a top view of the bone anchor assembly of FIG. 17;

FIG. 19 illustrates a perspective view of an fifth preferred embodimentof the bone anchor assembly of the present invention;

FIG. 19A illustrates a side cross-sectional view of the bone anchorassembly of FIG. 19;

FIG. 19B illustrates a perspective view of the body element of FIG. 19;

FIG. 19C illustrates a perspective view of the saddle element of FIG.19;

FIG. 19D illustrates a perspective view of the sleeve and bushingelement of FIG. 19A;

FIG. 20 illustrates a side cross-sectional view of a sixth preferredembodiment of the bone anchor assembly of the present invention;

FIG. 21 illustrates a perspective view of a seventh embodiment of a boneanchor assembly in accordance with the present invention;

FIG. 21A illustrates a side cross-sectional view of the anchor assemblyof FIG. 21;

FIG. 22 illustrates a side perspective view of an eighth embodiment of abone anchor assembly in accordance with the present invention;

FIG. 23 illustrates a perspective view of a fastener element and bonescrew in accordance with the embodiment of the bone anchor assembly ofFIG. 22;

FIG. 24 illustrates a side cross-sectional view of a fastener element ina first state with a bone screw captured therein in accordance with thebone anchor assembly of FIG. 22;

FIG. 25 illustrates a side cross-sectional view of a fastener element ina second state with a screw captured therein being inserted into thebody element in accordance with the bone anchor assembly of FIG. 22;

FIG. 26 illustrates a side cross-sectional view of the bone anchorassembly of FIG. 25 in a locked position within the body element;

FIG. 27 illustrates a cross-sectional view of the bone anchor assemblyof FIG. 22 with a two-piece locking cap;

FIG. 28 illustrates a perspective view of a screw and fastener elementof a ninth embodiment of a bone anchor assembly in accordance with thepresent invention;

FIG. 29 illustrates a side cross-sectional view of the ninth bone anchorassembly of FIG. 28 including the screw and locking element in a lockedposition in the body element;

FIG. 30 illustrates a perspective view of a tenth embodiment of a boneanchor assembly in accordance with the present invention;

FIG. 31 illustrates a side cross-sectional view of the bone anchorassembly of FIG. 30;

FIG. 32 illustrates a side perspective view of an eleventh embodiment ofa bone anchor assembly in accordance with the present invention;

FIG. 33 illustrates a side cross-sectional view of the bone anchorassembly of FIG. 32 prior to assembly of the screw; and

FIG. 34 illustrates a twelfth embodiment of the bone anchor assembly inaccordance with the present invention.

DETAILED DESCRIPTION OF THE INVENTION

Certain terminology is used in the following description for convenienceonly and is not limiting. The words “right”, “left”, “lower”, “upper”,“below”, “above”, “top”, and “bottom” designate directions in thedrawings to which reference is made. The words “inwardly” or “distally”and “outwardly” or “proximally” refer to directions toward and awayfrom, respectively, the geometric center of the bone anchor systemand/or assembly, the described instruments and designated parts thereof.The words, “anterior”, “posterior”, “superior”, “inferior”, “medial”,and “lateral” and related words and/or phrases designate preferredpositions and orientations in the human body to which reference is madeand are not meant to be limiting. The terminology includes theabove-listed words, derivatives thereof and words of similar import.

Certain exemplary embodiments of the invention will now be describedwith reference to the drawings. In general, such embodiments relate to apreferred bone anchor system including preferred bone anchor assembliesand related instruments by way of non-limiting example for use in spinalfixation which generally includes a rod-receiving channel configured andarranged to receive and secure the position of a spinal rod. Preferablythe system may include (1) bone anchor assemblies that have a channelfor receiving the spinal rod from the side, referred to as aside-loading bone anchor or side-loading bone anchor assembly, and/or(2) bone anchor assemblies that have a channel for receiving the spinalrod from the top, referred to as a top-loading bone anchor ortop-loading bone anchor assembly. Preferably, the top-loading boneanchor assemblies can be used with side-loading bone anchor assembliesin the same system, and for the same spinal rod. The bone anchorassemblies may also include bodies having integral spinal rod elementsor the bone anchor assemblies of the present invention may be used withbone anchor assemblies that have integral spinal rod elements.

Referring to FIGS. 1-3, bone anchor or bone fixation assembly 100generally includes a bone anchor 10 (shown as a bone screw), a body 20,a bushing 40, and a locking cap 92, which includes a saddle 70. As willbe described in greater detail below, the anchor assembly 100 preferablyenables in-situ assembly of the bone anchor 10 to the body 20. That is,preferably, the bone anchor assembly 100 is configured so that in use,the bone anchor 10 may be secured to a patient's vertebra 200 prior tobeing received within the body 20. The bone anchor assembly 100preferably enables a surgeon to implant the bone anchor 10 without thebody 20 and bushing 40 pre-assembled to the bone anchor 10. By enablingthe surgeon to implant only the bone anchor 10 without the body 20, theanchor assembly 100 maximizes visibility and access around the anchoringsite.

Once the bone anchor 10 has been secured to the patient's vertebra 200,the body 20 and bushing 40, which is retained in the body 20, may“click-on” to the bone anchor 10. Accordingly, in the preferred anchorassembly 100, the bone anchor 10 enters the body 20 through the loweropening 24 of the body 20. Once the body 20 and bushing 40 have beenclicked onto the bone anchor 10, a spinal rod 101 may be inserted into arod receiving channel 27, 29 formed in the body 20, and the locking cap92 may be used to secure the position of the rod 101. Alternatively, thebone anchor assembly 100 (e.g., the body 20, bushing 40, and bone anchor10) may be provided pre-assembled using components identical to orsubstantially similar to the components described herein. The body 20,and in particular the rod receiving channel 27 may be configured forside-loading as shown in FIGS. 1-1A, or the rod receiving channel 29 maybe configured for top-loading as shown in FIG. 2-2A. Additionally, thebushing and body sub-assembly may be popped-off of the bone anchor 10in-situ by arranging and positioning the bushing 40 in aloading/unloading position relative to the body 20, as shown in FIGS. 5Aand 8, and removing the bushing/body sub-assembly from the bone anchor10, as will be described in greater detail below.

While the anchor assembly 100 will be described as and may generally beused in the spine (for example, in the lumbar, thoracic or cervicalregions), and in particular attached to the vertebra 200 as shown inFIG. 3, those skilled in the art will appreciate that the anchorassembly 100 may be used for fixation of other parts of the body suchas, for example, joints, long bones, ribs, or bones in the hand, face,feet, toe, extremities, cranium, mandible, etc., and may be used fornon-orthopedic applications and non-medical applications.

As shown in FIG. 3, bone-anchoring system 5 may include several anchorassemblies 100 and may be used with one or more spinal rods 101 tosecure and interconnect several vertebrae 200. It should be understoodthat the spinal rod 101 may constitute or include, but is not limitedto, a solid rod, a non-solid or hollow rod, a flexible or dynamic rod,etc. It should be understood that bone anchor system 5 is not limited inuse to any particular type of spinal rod 101 and any elongated elementor support member of any shape and configuration is contemplated.

Referring to FIGS. 1-3, the bone anchor 10 preferably is in the form ofa bone screw. Alternatively, however, the bone anchor 10 may be, forexample, a hook, pin, blade, nail, tack, stake or other fastener suchas, a clamp, an implant, etc.

The bone anchor 10 preferably includes an enlarged, curvate head 14 andan externally threaded shaft portion 15 for engaging the patient'svertebra 200. The specific features of the shaft 15 including, forexample, thread pitch, shaft diameter, shaft shape, etc. may be varied,and it would be apparent to one having ordinary skill in the art thatthe bone screw 10 is not limited to any particular features on or typeof shaft 15. The bone screw 10 may or may not be cannulated. The bonescrew 10 may also include a reduced diameter neck portion 16 between thehead 14 and the shaft portion 15, which facilitates the polyaxial natureof the bone fixation assembly 100. The bone screw 10 may further becannulated and fenestrated (not shown) such that openings extendoutwardly from a central hollow channel 12 in the cannulated screw for amultitude of potential uses, including, but not limited to, urgingmaterial out of the screw during injection, drawing fluid into thecentral hollow channel from the sides of the screw to extract materialadjacent the screw, or passing through instruments or implants.

Referring to FIGS. 1A and 2A, the enlarged head 14 preferably has acurvate or semi-spherical shape to facilitate rotation and angulationwith respect to the bushing 40 before the bone screw 10 is locked to thebody 20, as will be described in greater detail below. The head 14 alsopreferably includes a drive surface 17 for receiving a corresponding tipformed on a drive tool, such as a screwdriver for rotating the bonescrew 10 into engagement with the patient's vertebra 200. The drivesurface 17 may have any form now or hereafter known including, but notlimited to, an external hexagon, a star drive pattern, a Phillips headpattern, a slot for a screw driver, a threading for a correspondinglythreaded post, etc. Preferably, as shown, the drive surface 17 iscomprised of a first tool interface 13, but is not so limited and may becomprised of an external drive feature that engages a female-type driver(not shown). The specific shape of the drive surface 17 or first toolinterface 13 may be chosen to cooperate with the corresponding drivetool.

As disclosed in International App. No. PCT/US2008/070670, entitled“Polyaxial Bone Fixation Element,” filed Jul. 21, 2008, the entirecontents of which are incorporated by reference herein, the head 14 mayalso include a second tool interface or a sleeve interface 18. Thesecond tool interface 18 may include threading (as shown) or otherfeatures to interact with instruments, such as a drive instrument.

Referring to FIGS. 1A, 2A and 4-4F, the body 20 may generally bedescribed as a cylindrical tubular body having a rod receiving channel27, 29, a longitudinal axis 32, an upper end 33 having an upper opening23, a lower end 34 having a lower opening 24, and an axial bore 22preferably substantially coaxial with the longitudinal axis 32 of thebody 20. The axial bore 22 extends from the upper opening 23 to thelower opening 24 and has a lower chamber 36 proximate the lower end 34.The axial bore 22 at the upper opening 23 has a first diameter d1 andthe bore 22 at the lower opening 24 has a second diameter d2, which ispreferably smaller than the first diameter d1. The second diameter d2 ispreferably sized and configured so that the enlarged head 14 of the boneanchor 10 may be passed through the lower opening 24 of the body 20. Thebody 20 also includes an outer surface 132 and an inner surface 28. Theinner surface 28 of the axial bore 22 preferably includes a plurality ofthreads 21 in the upper end 33 for engaging the locking cap 92, 190.Alternatively, the body 20 and, in particular, axial bore 22 may havenearly any mounting structure for engaging the locking cap 92, 190including, but not limited to, external threads, cam-lock, quarter lock,clamps, lugs, bayonets, etc.

In the side-loading bone anchor, a rod-receiving channel 27 is formed inthe side of body 20 to receive the spinal rod 101. In the top-loadingbone anchor, a rod-receiving channel 29 is formed in the top of the body20 to receive the spinal rod 101. The rod-receiving channel 27, 29 isgenerally transverse, preferably perpendicular, to the longitudinal axis32 of the body 20 and communicates with and connects to the axial bore22. The rod receiving channel 27, 29 may be sized and constructed toreceive a spinal rod 101 of any size or configuration now known or laterdiscovered.

Referring to FIGS. 4-4F, the lower chamber 36 may include an upperportion 122 having a maximum third diameter d3 and a lower portion 127having the lower opening 24. The lower opening 24 is configured suchthat second diameter d2 is preferably smaller than the third diameter d3of the upper portion 122 of the lower chamber 36. The diameter d3 of theupper portion 122 of the lower chamber 36 is preferably larger than thediameter d1 of the axial bore 22. In this manner, the bushing 40preferably may be inserted through the upper end 33 into the axial bore22, but is prevented from falling out of the lower opening 24 at thelower end 34 of the body 20. The lower chamber 36 is additionallypreferably sized and configured such that the diameter in the lowerchamber 36 may be variable depending upon the region or zone between thethird diameter d3 and the second diameter d2.

The lower chamber 36 may also preferably include one or more lowerchamber surfaces 37 in the lower end 34 of the body portion 20, aninterference zone 59, and a rotation zone 39. The lower chamber surfaces37 of the body preferably include a first curvate or spherical concavesurface 144 for accommodating bushing 40 having an outer surface 50. Thefirst spherical surface 144 has a radius of curvature r1 that ispreferably centered on the longitudinal axis 32 of the body 20.Preferably, a second spherical surface 145 may be provided. The secondspherical surface 145 is positionable adjacent and above the firstspherical surface 144 and preferably has a radius of curvature r2centered on the longitudinal axis 32 of the body 20. The radius ofcurvature r2 is preferably different than, and preferably larger than,the radius of curvature r1. The diameter of the lower chamber 26 in theregion of the second concave surface 145 is preferably larger than thediameter of the lower chamber 36 in the region of the first concavesurface 144. The interference zone 59 and rotation zone 39 arepreferably located in the upper portion 122 of the lower chamber 36 andwill be further discussed below.

Referring to FIGS. 5-5A, the bushing 40 is preferably placed into thelower chamber 36 of the body 20 during manufacture and is permitted tomove within a portion of the axial bore 22 formed in the body 20 betweena loading/unloading position (FIG. 5A) and a locked position (FIG. 5).That is, the bushing 40 is preferably movably positionable within thebody 20 between a position where the bone anchor 10 can be connected toor unconnected from the bushing 40 (loading/unloading/unlockedposition), and a position where the bushing 40 is locked with respect tothe bone anchor 10 (locked position). However, the bushing 40 ispreferably constructed such that it may be inserted into the body 20through the upper opening 23, but is prevented from exiting through thelower opening 24. Once the bushing 40 is placed and assembled into thebody 20, the bushing 40 is preferably retainable within the body 20 suchthat the bushing 40 is generally prevented from either (1) passing backup through the upper opening 23 formed in the body 20; (2) passingthrough the lower opening 24 formed in the body 20; or (3) passingthrough the rod receiving channels 27, 29.

Referring to FIGS. 6-6B and 7-7A, the bushing 40 preferably includes anupper end 47 having an upper opening 54, a lower end portion 46 having alower opening 142, and a bore 48 that extends from the upper opening 54to the lower opening 142. A drive tool, such as, for example, a screwdriver, can be inserted through the bore 48 of the bushing 40 and intoengagement with the bone anchor 10 so that the bone anchor 10 may berotated into engagement with the patient's vertebra 200. The bushing 40also includes an exterior surface 55, which may be sized and configuredto contact the lower chamber surfaces 37 when the head 14 of the boneanchor 10 is secured within the bushing 40 in a locked position, as willbe detailed further below.

The lower end portion 46 of the bushing 40 preferably includes aninterior cavity 51 for receiving and securing the head 14 of the boneanchor 10 so that the bone anchor 10 can rotate polyaxially through arange of angles with respect to the bushing 40 and hence with respect tothe body 20 when in an unlocked or loading/unloading position. Theinterior cavity 51 formed in the bushing 40 preferably has a curvate orsemi-spherical shape for receiving the curvate or semi-spherical head 14of the bone anchor 10. The interior cavity 51 formed in the bushing 40is preferably constructed so that the bone anchor 10 can polyaxiallyrotate with respect to the bushing 40, when the bushing is in anunlocked position, and hence, with respect to the body 20.

The bushing 40 preferably also includes one or more slots 42 (shown as aplurality of slots, e.g., FIGS. 6-7A) extending from the lower endportion 46 thereof so that at least a portion of the bushing 40 is: (i)radially expandable so that the head 14 of the bone anchor 10 can beinserted through the lower opening 142 in the lower end portion 46 andinto the interior cavity 51 of the bushing 40 and (ii) radiallycompressible to compress or lock against the head 14 of the bone anchor10 when radial forces are applied thereto. In the preferred embodiment,the slots 42 define a plurality of flexible arms 45. Preferably eachflexible arm 45 includes a root end 52 and a terminal end 53. The slots42 may extend from the lower end 46, the upper end 47 or both ends 46,47. One slot 42 may extend the length of the bushing 40 creating acompressible spring clip.

Referring to FIGS. 7-7A and 8, in one preferred embodiment, the exteriorsurface 55 of the flexible arms 45 may form at least a portion of theouter surface 55 of the bushing 40 and is comprised of a curvate orspherical, convex surface 50 having an outer radius of curvature r5 forcontacting the lower chamber surfaces 37 of the body 20. The radius ofcurvature r5 of the bushing 40 is preferably different than the radiusof curvature r1 of the first spherical surface 144 of the lower chambersurfaces 37 such that a generally line contact is defined between thefirst spherical surface 144 and the exterior surface 55 of the bushing40 when the bushing 40 is positioned proximate the lower end 34 of thebody 20 in the locked position. The frusto-spherical convex surface 50of the bushing 40 preferably facilitates proper alignment of the bushing40 within the bore 22 of the body 20 to receive the head 14 of the boneanchor 10 without impediment.

Referring to FIGS. 5, 5A and 6-6A, in an alternative preferredembodiment, the outer surface 55 of the bushing 40 preferably includesthe spherical, convex surface 50 and one or more cylindrical zones 43,44. Referring to FIGS. 4 and 4B, the lower chamber surfaces 37 of thebody 20 may also include one or more cylindrical surfaces 128. The oneor more cylindrical surfaces 128 are preferably configured and arrangedto accommodate the one or more cylindrical zones 43, 44 of the bushing40. The one or more cylindrical surfaces 128 may be any height h1, butin the embodiment shown, are preferably approximately 1 mm in height andgenerally are preferably about 0.5 mm to about 2 mm. The cylindricalzones 43, 44 preferably have a height h2 of about 1 mm, and generallymay have a height of about 0.5 mm to about 2 mm although other valuesare contemplated.

Referring to FIGS. 6-7A, the cylindrical zones 43, 44 are provided toprevent the bushing 40 from angulating within the body 20 about an axisthat is perpendicular to the axis 32, which may be caused by a surgeonmanipulating the body 20 during surgery. That is, the cylindrical zones43, 44 on the bushing 40 in combination with the cylindrical zone 128 inthe body 20 preferably resist the bushing from angulating or toggling inthe body so that the longitudinal axis 49 of the bushing preferablyremains parallel and co-linear with the axis 32 of the body 20. Suchrotation could cause the body 20 to move toward the upper end 33 of thebody 20 in the axial bore 22, which may permit the body 20 to click-offthe head 14 of the bone anchor 10. The cylindrical zones 43, 44 may alsooffer further benefits. For example, when axial force is applieddownward on the upper end 47 of the bushing 40, the cylindrical zones43, 44 may inhibit the bushing 40 from protruding from the lower opening24 of the body 20. In this manner, the cooperating cylindrical surfaces128 and cylindrical zones 43, 44 may prevent the bushing 40 from jammingand the bushing 40 from becoming deformed and unusable. The cylindricalzones 43, 44 of the bushing 40 may also inhibit and resist the bushing40 from unlocking or releasing the head 14 of the bone anchor 10 afterthe body 20 and bushing 40 have been clicked onto the head 14 of thebone anchor 10. That is, the bushing 40 can translate upward in the body20 without releasing the locking force exerted by the body 20 on thebushing 40 since the bushing arms 45 remain in position and areprevented from expanding while the cylindrical surfaces 128 remain inthe cylindrical zones 43, 44.

As discussed, the bushing 40 is preferably placed and retained withinthe body 20 during the manufacturing process. To place and retain thebushing 40 in the body 20, the bushing 40 preferably may be providedwith structures, features, geometry and a configuration that interactsand interfaces with structures, features and geometry of the body 20. Inone preferred exemplary embodiment, the bushing 40, as shown in FIG. 6B,may be provided with one or more first wings 41 and one or more secondwings 56.

More specifically, as shown in FIG. 6B, the bushing 40 is preferablyprovided with a pair of first wings 41 extending from the exteriorsurface 55 of the bushing 40 and having a first wing width or arc lengthw1. The first wings 41 preferably extend generally perpendicular to thebushing axis 49 and are preferably spaced one hundred eighty degrees(180°) from one another. The bushing 40 preferably is also provided witha pair of second wings 56 having a second wing width or arc length w2,wherein w2 preferably is greater than the first wing width w1. That is,the second wings 56 are generally wider than the first wings 41. Thesecond wings 56 are also disposed on the exterior surface 55 of thebushing 40 and preferably extend generally perpendicular to the bushingbore 48. Each second wing 56 is positioned between and adjacent a firstwing 41 and are preferably spaced one hundred eighty degrees (180°) fromone another. The first, narrower wings 41 preferably have a wingdiameter wd1 that is greater than the second wing diameter wd2 of thesecond, wider wings 56. That is, the lip extension 57 of the first wings41 extends further than the lip extension 58 of the second wings 56.While the bushing 40 has been described and illustrated as having afirst pair of wings 41 and a second pair of wings 56, it should berecognized that one or more wings 41 (or no wings 41) and one or morewings 56 (or no wings 56) may be provided in different sizes, shapes,positions and configurations and that the bushing is not limited to thestructure and configuration shown and described.

While bushing 40 has been illustrated and described in FIGS. 1-7A asbeing generally one-piece, the bushing may comprise a multi-pieceelement as described and illustrated in FIGS. 19D and 20, and thebushing 40 is not limited to the structure, features or configurationshown.

With reference to FIG. 4, the body 20 additionally preferably includes ageometry and configuration that interacts and interfaces with thebushing 40 to retain the bushing 40 in the lower chamber 36 of the body20. The lower chamber 36, and preferably the upper portion 122 of thelower chamber 36, preferably includes an interference zone 59 and arotation zone 39. The rotation zone 39 is preferably disposed above thefirst spherical surface 144 and may be located above the secondspherical surface 145 or may include the entire second spherical surface145 or portions thereof. The interference zone 59 preferably is locatedabove the rotation zone 39 and includes major projections 31 and firststops 25 forming channels 134, 135. The interference zone 59 may alsooptionally include one or more second stops 26.

The major projections 31 preferably extend in the direction of thelongitudinal axis 32 of the body 20 and are disposed on the lowerchamber surface 37 in the interference zone 59. As will be described inmore detail below, the major projections 31 prevent rotation of thebushing 40 when the bushing is located in the interference zone 59.First stops 25 are disposed on the inner surface 37 at the top portionof the interference zone 59 above the major projections 31. The firststops 25 together with the major projection 31 generally resemble a“T-shape” when viewed from the side. The first stops 25, as will bedescribed below, retain the bushing 40 in the body 20 and providessupport to the bushing 40 when the bone anchor 10 is being clicked intothe body 20.

The preferred embodiment, as shown in FIGS. 4A and 4B, has four (4)major projections 31 and four (4) first stops 25 located above the majorprojections 31. The first stops 25 and the major projections 31 formfour (4) channels 134, 135 in the interference zone 59 for receiving thewings 41, 56 of the bushing 40. More specifically, in the embodiment ofFIGS. 4, 4A and 4B, the first stops 25 and major projections 31 form apair of first channels 134 spaced approximately one hundred eightydegrees (180°) apart having a first channel width or arc length CW1. Thefirst stops 25 and major projections 31 form a pair of second channels135 spaced approximately one hundred eighty degrees (180°) apart havinga second channel width or arc length CW2 such that the width CW1 of thefirst channels 134 are wider than the width CW2 of the second channels135. The difference in the width CW1 of the first channels 134 ascompared to the width CW2 of the second channels 135 preferably is theresult of the ends 140 of the first stops 25 extending circumferentiallymore into the second channels 135 than the first channels 134.

Optionally, one or more second stops 26, as shown in FIG. 4, may beprovided in the interference zone 59 below the first stops 25. Thesecond stops 26 preferably constitute projections 136 that extend intothe lower chamber 36 in the interference zone 59. In the embodiment ofFIGS. 4-4B, projections 136 forming the second stops 26 extend inwardfrom the inner surface 28 in first channels 134 but preferably do notextend inward as much as the first stops 25. The second stops 26preferably resist the head 14 of the bone anchor 10 from being dislodgedfrom the bushing 40 during adjustment of the bone fixation system and/orassembly as will be described in more detail later.

The bushing 40 is preferably preassembled and retained within the body20. To assemble the bushing 40 into the body 20, the first wings 41 andthe second wings 56 are sized and configured so that the bushing 40 maybe inserted through the upper opening 23 of the body 20 and down theaxial bore 22. The bushing 40 is further sized and configured such thatthe first wings 41 may be inserted down second channels 135 in theinterference zone 59 while the second wings 56 may be inserted down thefirst channels 134 in the interference zone 59. Preferably the firstwings 41 and second wings 56 of the bushing 40 are pushed down channels135 and 134 respectively, and past the first stops 25 withoutinterference. In addition, as the bushing 40 is pushed down the axialbore 22, the second wings 56 which have a smaller diameter (wd2) thanthe first wings 41 (wd1) are moved down the first channels 134 past theoptional second stops 26 without interference. The first wings 41 andsecond wings 56 are alongside the major projections 31 as the bushing 40is moved down the interference zone 59 to the rotation zone 39. As thebushing 40 is pushed down the interference zone 39, the wings 41, 56 andmajor projections 31 preferably prevent the bushing 40 from rotating orturning about its axis 49 and the axis 32 of the body 20. Preferably, inorder to push the bushing 40 down far enough so that the wings 41, 56are positioned in the rotation zone 39, the lower end 46 of the bushing40 is pressed into the lower chamber surfaces 37 of the lower portion127 of the lower chamber 36 so that the arms 45 of the bushing 40 arecompressed inward. Preferably, if the bone anchor 10 is captured in thebushing 40, the bushing 40 cannot be pushed down far enough in the lowerchamber 36 to permit the wings 41, 56 to be located within the rotationzone 39.

When the wings 41, 56 are positioned in the rotation zone 39, thebushing 40 may be rotated about axis 32/axis 49 such that first wings 41are positioned below and aligned with the first channels 134 and thesecond wings 56 are positioned below and aligned with the secondchannels 135. In the embodiment of FIGS. 5, 5A and 9, with the wings 41,56 positioned in the rotation zone 39, the bushing preferably is rotatedninety degrees (90), or two hundred seventy degrees (270) to align thefirst narrower wings 41 with the first wider channels 134 and the secondwider wings 56 with the second narrower channels 135, although in otherembodiments the bushing 40 may be rotated different amounts in order toalign the wings with the proper channels. With the first wings 41aligned with the first channels 134, and the second wings 56 alignedwith the second channels 135, the bushing 40 may be pushed up so thatthe wings 41, 56 are positioned in the interference zone 59. With thewings 41, 56 located in the interference zone 59, the arms 45 of thebushing 40 are predominantly located in the rotation zone 39 to permitassembly of the head 14 of the bone anchor 10 into the bushing 40 thatis contained within the body 20.

The bushing 40 may be retained in the loading position with the arms 45of the bushing 40 aligned with and located within the rotation zone 39by (1) the first stops 25 preventing the bushing from passing throughthe axial bore 22 and out of the upper opening 23 of the body 20, and(2) the interaction of the arms 45 of the bushing 40 with the lowerchamber surfaces 37 of the lower chamber 36 preventing the wings 41, 56from dropping into the rotation zone 39. Specifically, the bushing 40may be retained in the loading position because the stops 25 interferewith continued movement of the bushing 40 up the axial bore 22 and outof the upper opening 23 of the body 20. The second wings 56 interactwith and abut against the first stops 25 and prevent the bushing frombeing pushed up the axial bore 22 and out the upper opening 23 of thebody 20. More specifically, the edges 139 of the wider second wings 56interfere with the ends 140 of the first stops 25 preventing furtherupward motion of the bushing 40 (FIG. 9). The first narrower wings 41 inthe wider first channel 135 do not interfere or interact with the firststops 25. The major projections 31 prevent the bushing 40 from rotatingwhile in the interference zone 59. The lower end 53 of the arms 45 ofthe bushing 40 retain the bushing 40 in the loading position becausethey abut against the lower chamber surfaces 37 of the lower chamber 36before the bushing 40 drops far enough down in the interference zone 59for the wings 41, 56 to be located in the rotation zone 36.

If the optional second stops 26, as shown in FIG. 4, are provided in thefirst channels 134, the first wings 41 are pushed up past the secondstops 26 by elastically deflecting the wings 41 and/or second stops 26as the bushing 40 is pushed up into the interference zone 59. Theoptional second stops 26 will interact with the first wings 41 to alsoprevent the bushing 40 from sliding down into the rotation zone 39 ofthe lower chamber 36 so that the bushing 40 will be further retained inthe body 20. The bushing 40 is thus assembled to preferably position thebushing 40 within the body 20 so that the first and second wings 41, 56are located in the interference zone 59 between the first stops 25 andthe second stops 26 (see FIG. 8). In this manner the bushing 40 may beprevented from detaching from the body 20 because the second stops 26and the compressing of the bushing 40 inhibit the wings 41, 56 of thebushing 40 from moving back into the rotation zone 39 and rotating tosuch degree that it might be able to be pushed upwards in the bore 22and detach from the body 20.

Referring to FIG. 8, to interconnect or attach the bone anchor 10 to thebody 20, the body 20 is preferably provided with the bushing 40pre-assembled and in the loading position with the wings 41, 56 locatedin the interference zone 59 between the first stop 25 and the secondstop 26 so that the bushing arms 45 are predominately located in therotation zone 39. The head 14 of the bone anchor 10 is inserted into thelower opening 24 of the body 20 and into the interior cavity 51 of thebushing 40. After the head 14 of the bone anchor 10 is inserted into thecavity 51 of the bushing 40 and snapped into the bushing 40, the bushingand bone anchor subassembly is preferably moved down into the lowerchamber 36 of the body 20 to prevent the head 14 of the bone anchor 10from becoming dislodged from bushing 40.

Optional second stops 26 may assist in inhibiting the bone anchor andbushing sub-assembly from moving up into the chamber 36 where thebushing 40 can detach from the bone anchor 10. After the bone anchor 10is clicked onto the body 20 and captured within the bushing 40, thebushing and bone anchor sub-assembly is preferably pushed down in thelower chamber 36 so that the first wings 41 move pass the second stops26. An instrument may assist with moving the bushing and bone anchorsub-assembly past the second stops 26 by deflecting one or both of thefirst wings 41 and second stops 26, and/or providing sufficient force topush the bushing 40 down past the second stop 26. The wings 41, 56preferably would still be located in the interference zone 59 so thatthe bushing 40 is prevented from rotating about axis 49/axis 32 in thebody 20. The second stops 26 preferably would thereafter prevent thebushing 40 from moving up so that the bushing arms 45 would bepositioned into the rotation zone 39 where the bushing arms 45 canexpand and release the bone anchor 10. That is, the forces the boneanchor assembly 100 is likely to encounter during the surgery frommanipulation and adjustment by the surgeon is unlikely to force thefirst wings 41 up past the second stops 26. In this manner, the bushingand bone anchor sub-assembly can be positioned so that the first wings41 are below the second stops 26 so that the arms 45 are not expandableand cannot release the bone anchor 10, but the bone anchor 10 may stillbe movable and adjustable with respect to the body 20 and the spinal rod101.

Referring to FIGS. 1A, 2A and 8, once the head 14 of the bone anchor 10is received into the bushing 40, the bushing 40 may be moved downwardtoward the lower opening 24 of the body 20 to lock the head 14 of thebone anchor 10. As the bushing 40 moves downwards, the arms 45 of thebushing 40 come into contact with the one or more lower chamber surfaces37 in the lower chamber 36 of the body 20, which exert a force againstthe arms 45 of the bushing 40, causing the arms 45 to collapse aroundthe head 14 of the bone anchor 10 into a locking position, therebylocking the position of the bone anchor 10 relative to the body 20. Moreparticularly, as the bushing 40 moves downward, the bushing arms 45preferably contact the first spherical surface 144 which pushes andpreferably elastically deflects the bushing arms 45 radially inward sothat the arms collapse about the head 14 of the bone anchor 10.Preferably, a line contact or a contact band of limited width is formedbetween the bushing 40 and the first spherical surface 144. The lockingcaps 92, 190 as described below preferably control the locking action ofthe bushing 40.

Referring to FIGS. 1A, 5A, 10 and 21, the locking cap may preferably beeither a three-piece locking cap 92 (FIGS. 1A, 5A and 8) or a two-piecelocking cap 190 (FIG. 21). The locking cap 92, 190 is movable from anunlocked to a locked position to lock the bone anchor 10 and the rod 101in place. The three-piece locking cap 92 preferably permits separatelocking of the adjustability of the bone anchor 10 and the rod 101,whereas the two-piece locking cap 190 permits locking of theadjustability of the bone anchor 10 and the rod 101 in one step.

The locking cap 92, 190 includes a saddle 70 and a means for engagingthe body 20. The means for engaging the body 20 may include, but is notlimited to, an externally threaded cap, an internally threaded cap, aquarter-turn or partial-turn locking cap, cam-lock, bayonet and lug,two-piece set screw, etc. The saddle 70 of the locking cap 92, 190 inthe preferred embodiments includes a bore 170 and two saddle arms 73defining an inverse U-shaped channel 78. The saddle 70 preferably isinserted into and extends down the axial bore 22 of the body 20. Withthe saddle inserted into the axial bore 22, the U-shaped channel 78 issized and configured to fit at least partially over the spinal rod 101.The saddle arms 73 are preferably of sufficient length to extend intoand be received by the lower end 34 of the body 20, as will be laterdiscussed, to secure the position of the spinal rod 101. In analternative embodiment, the saddle 70 may have shorter saddle arms 73that extend partially over and around the spinal rod 101 (FIGS. 19A and20).

Referring to FIGS. 1A, 2A, 5A, 8 and 10, a three-piece locking cap 92 isprovided, having the saddle 70, a setscrew element, such as a setscrew90, and a threaded ring 60. The three-piece locking cap 92 may assumevarious configurations. In one configuration, as shown in FIGS. 1A, 2A,8 and 10, the setscrew 90 is received within the saddle 70 while inanother configuration, shown in FIG. 5A, the setscrew 70 is received inthe threaded ring 60. In both of these configurations the saddle 70 isinterconnected to and its operation (movement) is controlled by thethreaded ring 60. The saddle 70 may be interconnected to the threadedring 60 in many different ways and the threaded ring 60 is preferablyindependently rotatable with respect to the saddle 70. In thethree-piece locking cap embodiment of FIGS. 1A, 2A, and 8 where thesetscrew 90 is received in the saddle, the threaded ring 60 as shown inFIG. 12 includes a bore 62, one or more ledges 63, and exterior threads61. The one or more ledges 63 of the threaded ring 60 are formed on theinner surface 69 of the threaded ring 60. The threaded ring 60 in thisembodiment does not include interior threads in the bore 62. Theexterior threads 61 of the threaded ring 60 are threadably engagablewith the interior threads 21 of the body 20. The saddle 70 is providedwith a ledge 87 disposed proximate the upper end 88 of the saddle 70that extends outward and is preferably capable of interlocking with theledge 63 of the threaded ring 60 to interconnect the threaded ring 60 tothe saddle 70. The saddle 70 additionally has internal threads 71 in thebore 170. The setscrew 90 includes external threads 93 capable ofthreadably engaging the internal threads 71 of the saddle 70. Thethreaded ring 60, saddle 70 and setscrew 90 are preferably preassembledas a unit for use during the implantation of the anchor assembly 100.Alternatively the threaded ring 60, saddle 70 or set screw 90 may besupplied and assembled during the surgical implantation of the boneanchor assembly 100, or supplied as sub-assemblies where the set screw90 is supplied connected to the saddle 70, or the saddle 70 is suppliedconnected to the threaded ring 60, or other alternative sub-assemblies.

With reference to FIGS. 1A, 2A and 8, to lock the adjustability of thebone anchor 10, once the rod 101 is placed into the rod receivingchannel 27, 29, the three-piece locking cap 92 may be placed into theupper opening 23 of the body 20 with the U-shaped channel 78 created bythe saddle arms 73 placed over the spinal rod 101. The threaded ring 60may then be threadably engaged with the threads 21 of the body 20 toconnect the locking cap 92 to the body 20. By engaging the locking cap92 with the body 20 the rod-receiving channel 27, 29 is closed and thespinal rod 101 is captured and retained in the bone anchor assembly 100but is still movable with respect to the body 20 and can angulate andslide in the body 20. To lock the movement of the spinal rod 101 and thebone anchor 10 with respect to the body 20, the threaded ring istightened and moves downward in the body 20, from an unlocked positionto a locked position. As the threaded ring 60 is moved further downwardin the body 20, from an unlocked to a locked position, the threaded ring60 pushes down on the saddle 70 which in turn pushes down on the bushing40, causing the arms 45 of the bushing 40 to collapse around the head 14of the bone anchor 10, thereby moving the bushing 40 to a lockedposition and securing the position of the bone anchor 10 with respect tothe body 20. Thus, the threaded ring 60 controls the locking of the boneanchor 10. To lock the rod 101 in place, the setscrew 90 is tightenedand as the setscrew 90 moves down the bore 170 of the saddle, the bottomsurface 95 of the setscrew 90 pushes down on the rod 101, therebysecuring the position of the rod 101. This configuration provides thebenefit of the anchor assembly 100 having a low profile when assembled.Other benefits include stable guidance of the saddle, a permanentpreloaded saddle which may promote stability, and in the top-loadingembodiments, tightening of the set-screw should result in little to nosplaying.

In the alternative embodiment where the threaded ring 60, saddle 70 andset screw 90 are provided as separate elements to be assembled duringimplantation of the bone anchor assembly 100, the saddle 70 may beplaced into the upper opening 23 of the body 20 over the rod 101. Thethreaded ring 60 may then be placed over the saddle 70 and threadablyengaged with the threads of the body 20. As the threaded ring 60 isrotated and moved downward into the body 20 it both pushes down on thesaddle and receives the upper end 88 of the saddle 70 into the bore 62of the threaded ring. As the threaded ring 60 moves into the lockedposition, the adjustability and movement of the bone anchor 10 withrespect to the body 20 is locked, and the ledge 63 of the threaded ringis also clipped into the ledge 87 of the saddle 70, attaching thethreaded ring 60 to the saddle 70. To lock the rod 101 in place, thesetscrew 90 is placed into the bore 170 of the saddle 70 and theexternal threads 93 of setscrew 90 are placed into engagement with theinterior threads 71 of the saddle 70. The setscrew 90 is then tightenedto lock the rod in place as described above.

With reference to FIG. 5A, in an alternative configuration of thethree-piece locking cap 92, the setscrew 90 is positioned within athreaded ring 260 (FIG. 12A), wherein the threaded ring 260 engages andinterconnects with the saddle 70. The threaded ring 260 includes anupper end 265, a lower end 264, a bore 261, interior threads 263 in thebore 261, and exterior threads 61, which mate with threads on the body20. The threaded ring 260 includes one or more ledges 262 forming one ormore grooves 268 are disposed on its exterior surface proximate thelower end 264 of the threaded ring 260. The saddle 70 is provided withan internal recess 171 formed in the inner surface of the bore 170 ofthe saddle 70 proximate the upper end 88 of the saddle 70 which has aprojection 172 that extends inward toward the center of bore 170. Theprojection 172 in the recess 171 preferably is capable of interlockingwith the one or more ledges 262 and grooves 268 of the threaded ring 260to interconnect the saddle 70 to the threaded ring 60. The interiorthreads 263 of the threaded ring 260 are capable of threadably engagingthe external threads 93 of the setscrew 90. The threaded ring 60, saddle70 and setscrew 90 are preferably preassembled as a unit for use duringthe implantation of the anchor assembly 100. Alternatively, the threadedring 60, saddle 70 or set screw 90 may be supplied and assembled duringthe surgical implantation of the bone anchor assembly 100, or suppliedas sub-assemblies where the setscrew 90 is supplied connected to thethreaded ring 60, or the saddle 70 is supplied connected to the threadedring 60, or other alternative sub-assemblies.

With reference to FIG. 5A, to lock the adjustability of the bone anchor10, once the rod 101 is placed into the rod receiving channel 27, 29,the three-piece locking cap 92 may be placed into the upper opening 23of the body 20 over the rod 101. The threaded ring 260 may then bethreadably engaged with the threads 21 of the body 20 to connect thelocking cap 92 to the body 20. By engaging the locking cap 92 with thebody 20 the rod-receiving channel 27,29 is closed and the rod 101 isretained in the body 20 but is still movable with respect to the body 20and can angulate and slide in the rod-receiving channel 27, 29. Inaddition the bone anchor 10 can still angulate and move with respect tothe body 20. To lock the movement of the rod and the bone anchor withrespect to the body 20, the threaded ring 260 is tightened and movesdownward in the body 20, from an unlocked to a locked position, andpushes down on the saddle 70. The saddle 70 in turn pushes down on thebushing 40, causing the arms 45 of the bushing 40 to collapse around thehead 14 of the bone anchor 10, thereby moving the bushing to a lockedposition and securing the position of the bone anchor 10 with respect tothe body 20. To lock the rod 101 in place, the setscrew 90 is tightenedwhich moves the setscrew 90 down the bore 261 of the threaded ring 260so that the bottom surface 95 of the setscrew 90 pushes down on the rod101, thereby securing the position of the rod 101. One of the advantagesof having the setscrew 90 threaded into the threaded ring 60 is thatreleasing the locking cap 92 by untightening the threaded ring 60unlocks both the rod and the bone anchor in one operation.

As described above in connection with the three-piece locking cap 92 ofFIGS. 1A, 2A and 8, the pieces of locking cap 92 shown in FIG. 5A may beindividually assembled into the body 20 during implantation of the boneanchor assembly 100 and the procedure is substantially similar to theprocedure described above but the setscrew 90 will be inserted into thethreaded bore of the threaded ring 60 rather than the threaded bore ofthe saddle 70.

Referring to FIG. 12-13, the threaded ring 60, 260 and set screw 90 alsopreferably include drive surfaces 64, 94 (FIGS. 12-13) for engagingcorresponding drive tools for securing (e.g., threading) the threadedring 60 onto the body 20. The drive surfaces 64, 94 may take on any formnow or hereafter developed for such purpose, including, but not limitedto, an external hexagon, a star drive pattern, a Phillips head pattern,a slot for a screw driver, a threading for a correspondingly threadedpost, etc. The drive surfaces 64, 94 may be one or more internalrecesses. The specific shape of the internal recess may be chosen tocooperate with the corresponding drive tool. The drive surfaces 64, 94may also be configured to include the first and second tool interfacesas were described above in connection with bone anchor 10.

Alternatively, with reference to FIG. 27, a two-piece locking cap 190may be provided. The two-piece locking cap 190 includes saddle 70′ and ameans for engaging the body 20. The means for engaging the body 20 mayinclude, but is not limited to, an externally threaded cap, aninternally threaded cap, a quarter-turn or partial-turn locking cap,cam-lock, bayonet and lug, two-piece set screw, etc. In FIG. 21 themeans for engaging the body includes locking element 191. The lockingelement 191 is substantially cylindrical shaped and includes a bottomsurface 192 and external threads 61 which are engagable with theinternal threads 21 of the body 20. While a threaded connection betweenthe locking element 191 and the body 20 is illustrated and described,any structure for engaging the locking element 191 to the body 20 may beprovided, including, but not limited to, external threads, cam-lock,quarter lock, clamps, lugs, bayonets, etc. The locking element 191 alsopreferably includes one or more projections 193. Saddle 70′ has arod-receiving channel 78 and saddle arms 73. Saddle 70′ interconnectswith the locking element 191 and preferably has a top portion 173 havingone or more top recesses 172 constructed and arranged to receive orengage the one or more projections 193 of the locking element 191 toconnect the saddle 70′ to the locking element 191. The saddle 70′ may beconnected to the locking element 191 is a number of ways including snaplock, corresponding grooves and projections, etc. Preferably, the saddle70′ is independently rotatable with respect to the locking element 191.The two-piece locking cap 190 may likewise include drive surfaces 194for engaging corresponding drive tools for securing (e.g., threading)the locking cap 190 onto the body 20.

Two-piece locking cap 190 preferably permits both locking of the rod andthe adjustability of the bone anchor 10 in one step. Once the spinal rod101 is placed into the rod-receiving channel 27, 29, the locking cap 190may be placed into the upper opening 23 of the body 20 over the spinalrod 101 to close the rod-receiving channel 27, 29. The locking element191 is then threaded into the body 20, so that the rod 101 is movablyretained in the rod-receiving channel 27, 29 and the bone anchor 10 canangularly adjust relative to the body 20. Once the rod 101 has beeninserted and loosely closed in by the locking cap 190, the bushing 40preferably can no longer be pushed back into the loaded position duringmanipulation by a surgeon to orient the system in the patient's spine.The body 20 is loosely but securely connected with the bone anchor andthe bone anchor preferably can no longer accidentally pop off duringmanipulation of the spinal rod 101 or the bone anchor assemblies 100 orother parts of the system 5. To lock the bone anchor assembly 100, thelocking element 191 is moved downward in the bore 22 of the body 20, sothat the bottom surface 192 of the locking element 191 pushes down onthe saddle 70, which in turn pushes down on the rod 101 and the bushing40, thereby securing the position of both the bone anchor 10 and the rod101.

When the locking cap 92, 190 is locked, the body 20 and the saddle 70may splay or twist due to the forces and moments required to lock spinalrod 101, bone anchor 10, and locking cap 92, 190. Each of the sideloading bone anchor assemblies, shown for example in FIGS. 1, 1A, andthe top-loading bone anchor assemblies, shown for example in FIGS. 2,2A, have potential splaying problems due to their inherent geometry. Inthe top-loading embodiment, because the rod-receiving channel 29 formstwo upright members that are unconnected at the top, when the spinal rod101 and bone anchor 10 are locked by tightening the locking cap 92, 190without the benefit of counter torque on the body, the upright membersare prone to separating and twisting. In the side loading bone anchorassemblies because the rod-receiving channel 27 comes in from the side,the body 20 forms an enclosed ring at the top portion supported by asingle stanchion or upright member connected to the closed ring. As aresult, tightening of the locking cap exerts eccentric forces, momentsand tends to twist and splay the closed ring about the single stanchionand upright member. Various features may be incorporated into the anchorassembly 100 to resist or prevent the body 20 and saddle 70 fromsplaying or twisting.

Preferably in the side-loading bone anchor assembly 100, to resistsplaying of the body and saddle, the body 20 may include one or more armrecesses 126 for receiving the lower portion 74 of the saddle arms 73.The arms 73 of the saddle 70, as shown in FIGS. 1A, 2A and 5A,preferably are sized and configured so that they are of sufficientlength to extend into the arm recesses 126 when the saddle 70 is placedin the bore 22 of the body 20. Preferably, the lower portion 74 of thesaddle arms 73 fit into the recesses 126. In this manner, the lower end74 of the saddle arm 73 that extends past the side opening 143 of therod receiving channel 27 is positioned between the bushing and the bodyand may be at least partially enveloped or “locked in” by one of the armrecesses 126 to hold the arm 73 in the body 20 and prevent or resist thearms 73 of the saddle 70 from splaying when the locking cap 92, 190 islocked. This feature of the saddle arms 36 extending into a recessformed in the body 20 may be applied to the top-loading bone anchorassemblies as well.

The extension of the saddle arms 73 into the lower chamber 36 of thebody 20 may take many forms. In one example, as shown in FIGS. 5, 5A,the inner surface 28 of the body 20 forming the recess 126 in the lowerend 34 of the body 20 that contacts the lower portion 74 of one of thesaddle arms 73 may be relatively smooth, curved wall surface 35 havingsubstantially no projections or channels. Also, as shown in FIGS. 1A and5A, the lower portions 74 of the saddle arms 73 that are received intothe recesses 126 preferably are provided with perpendicular bushinginterface surfaces 76 that contacts the exterior surface 55 of thebushing 40. The perpendicular bushing interface surface 76 is disposedat the lower portion 74 of the arms 73 of the saddle 70. Theperpendicular bushing interface surface 76 preferably includes asubstantially flat horizontal bottom surface 174, a substantiallyvertical side surface 175 and a substantially flat planar horizontalsurface 177, forming a notch 180. When the saddle 70 is placed into thebore 22 of the body 20, the bottom surface 174 may contact the wings 41of the bushing 40, the side surface 175 may contact the exterior surface55 of the bushing 40 proximate the upper end 47 and the horizontalsurface 177 may contact the top surface 89 of the bushing 40. Dependingupon the strength of the wings 41, the primary force exerted on thebushing 40 by the saddle arms 73 is preferably on the top surface 89 ofthe bushing 40. In this manner the saddle arms 73 interface with andapply force to the bushing 40 primarily through perpendicular surfaces.

Referring to FIG. 2A, the saddle 70 may alternatively be provided withan oblique bushing interface surface 75. The oblique bushing interfacesurface 75 is disposed at the lower portion 74 of the arms 73 of thesaddle 70. The oblique bushing interface surface 75 preferably includessubstantially flat bottom surface 174 and an oblique side surface 176.The bottom surface 174 of the saddle 70 is substantially flat and maycontact the wings 41 of the bushing 40. The oblique surface 176 contactsthe exterior surface 55 of the bushing 40 proximate the upper end 47.The bushing 40 may be provided with an oblique surface 86 that interactswith the oblique bushing interface surface 75. The lower portion 74 ofthe saddle arms 73 may additionally be supplied with a substantiallyflat horizontal planar surface 177 forming a notch 180 that may contactthe top surface 89 of the bushing as the saddle arms 73 move down intothe lower chamber 36 of the body 20. The oblique shape of the obliquebushing interface surface 75 may facilitate easier aligning of thesaddle 70 within the bore 22 of the body 20 than the perpendicularbushing interface surface 76. Again, depending upon the strength andflexibility of the wings 41, preferably the primary force applied to thebushing by the saddle arms 73 is to the top portion of the bushing 40rather than through the wings 41.

Side-loading bone anchor assemblies 100 are also prone to splayingbecause of their inherent geometry creates an eccentric line of actionfor the forces. Referring to FIGS. 1A and 16-16A especially whenutilizing a body 20 with a side-loading rod receiving channel 27, thebody 20 preferably includes a recess 30 to prevent splaying of thesaddle 70 and/or body 20. The recess 30 is preferably provided on theinner surface 28 at the lower end 34 of the body 20. The lower end 34 ofthe body additionally may be provided with inclined surface 38. Thesaddle 70 may additionally be provided with a protrusion 72 at the lowerportion 74 of one of the saddle arms 73 configured to engage the recess30 in the body 20. The saddle arm 73 may further be configured toinclude inclined surface 77 to interact with inclined surface 33 in thebody 20.

When the setscrew 90 is tightened to lock the spinal rod 101, the saddle70 has a tendency to rotate due to friction between the threads of thesaddle 70 and the setscrew 90. Rotation of the saddle 70 is prevented bythe rod, but the body 20, and in particular the top portion 33 of thebody 20 above the opening 19 and side rod-receiving channel 27, tends tosplay and move away from the lower portion 34 of the body 20. Inaddition, the saddle arm 73 where the side opening 19 is provided tendsto move up and splay. As the saddle arm 73 starts to move up, outwardand away (the saddle arm 73 has a tendency to move in path similar to anarc), the protrusion 72 on the saddle arm 73 moves into the recess 30and the inclined surfaces 38, 77 interlock to prevent further splayingof the body 20 and the saddle arm 73. The recess 30 in the body 20 maybe provided above the protrusion 72 when the saddle 70 is locked in thebody 20 and the setscrew 90 has not yet been tightened. In one exemplaryembodiment, the recess 30 may be about one to about two millimeters(about 1-2 mm) above the protrusion 72 when the saddle 70 locks thebushing 40 and bone anchor 10 in the body 20.

The engagement of the protrusion 74 with the recess 30 minimizes anysplaying of the saddle arms 73 caused by an axial force generated whenthe setscrew 90 is rotatably tightened whereby forces act on the saddle70, pushing the arms 73 of the saddle 70 outward with respect to thebore 22. While the protrusion 72 has been shown and described withinclined surface 77, and recess 30 has been shown and illustrated withinclined surface 38, the protrusion 72 and recess 30 may be providedwith perpendicular interacting surfaces, or other interacting andinterfacing surfaces and configurations.

In top-loading bone anchor assemblies 100 (e.g., FIG. 2-2A), splaying ofthe arms 73 of the saddle 70 from an axial force being applied to thesaddle 70 when the locking cap 92, 190 is placed in the locked positionmay be prevented and/or at least inhibited because both arms 73 of thesaddle 70 are supported along their length by the body 20, and by thearms extending into the recess 126 formed in the body 20. When thesetscrew is twisted in the saddle 70, the saddle 70 has a tendency totwist and rotate due to friction from the threads. Rotation of thesaddle however is prevented by the spinal rod, but the spinal rod andthe rotation forces have a tendency to splay the saddle arms 73.Splaying of the saddle 70 is resisted because the saddle arms 73 extendinto the recesses 126 which hold the ends of the arms 73 in position inthe lower portion 34 of the body 20.

Referring to FIGS. 14-15, in another preferred embodiment, to prevent orminimize the splaying of the saddle arms 73 or splaying or twisting ofthe body 20, particularly in top-loading bone anchor assemblies, thesaddle 70 may be constructed and arranged to be form-fitted to the sizeand shape of the body 20. That is, the saddle 70 includes an exteriorsurface 81 that maximizes contact between exterior surface 81 of thesaddle 70 and the inner surface 28 of the body 20 when the saddle 70 isplaced into the bore 22 of the body 20 and locked in place by thelocking cap 92, 190. Usually, when the locking cap 92, 190 is tightened,the friction between the threads of the body 20 and locking cap 92, 190may cause the body 20 to rotate or twist. The geometry of this “formfitted” saddle 70 controls and mitigates this rotation or twistingbecause it better integrates the body 20 and locking cap 92, 190,thereby permitting less movement of each individual component (e.g., thebody 20 or the saddle 70). That is, the saddle 70, and particularly thesaddle arms 73 are form-fit to the geometry of the bore 22 in the body20. The force tending to twist the body 20 is transmitted to andresisted by the saddle arms 73 and the inverse U-shaped channel 78 ofthe saddle 70. The force tending to twist the body 20 is transmitted tothe saddle arms 73 which because of their form-fit and integration intothe body 20 creates a stronger construct. The saddle 70 is held inposition by the rod 101 and the bushing 40 such that the saddle 70supports the body through the form-fit and extra mass and strength ofthe saddle arms 73 which resists twisting of the body 20.

To maximize the effectiveness of the saddle 70 with the form-fittedexterior surface 81, the exterior surface 81 of the saddle arms 73preferably fill any recess and space formed in the axial bone 22 inorder to provide more mass and material to better support the body 20 bycreating a more solid form. In addition, to maximize the effectivenessof the form-fitted exterior surface 81, the exterior surface 81 of thesaddle arms 73 preferably contacts the inner surface 28 at substantiallyright angles. That is, the exterior surface 81 of the saddle 70 may bearranged and configured to have a side surface 83 that is substantiallyperpendicular to the back surface 84 of the saddle arms so that thecross-section of the arms 73 are substantially square or rectangularshaped, as shown in FIG. 14. The body 20 is likewise formed withperpendicular surfaces to correlate and match surfaces 83, 84 and sothat the saddle and body are close-fitting. Such a shape optimallyprevents twisting of the body 20 and saddle 70. That is, as the lockingcap 92, 190 is tightened which tends to twist the body, the body 20transfers the force to the saddle 70. Since the saddle 70 is form-fittedvery little to no twisting of the body 20 occurs before the force istransmitted to the saddle 70 whereby the saddle 70 helps to resist thetwisting. Alternatively, the exterior surface 81 of the saddle 70 may bearranged and configured to have a substantially oblong or oval shape, asshown in FIG. 11, or other non-symmetrical or keyed shapes, whichbecause of the form-fit between the body 20 and the saddle 70 resistssplaying of the upright members of the top loading body 20. Other shapesand configurations of the saddle 70 and the interfacing shape of theinner surface 28 of the body 20 are contemplated and the saddle armshapes are not limited to the shapes shown and described. Theform-fitting of the saddle 70 and body 20 can also be applied toside-loading bone anchor assemblies.

An alternative top-loading bone anchor assembly 100 with features toresist and prevent splaying is shown in FIGS. 17 and 18. The body 20 inthe embodiment of FIGS. 17 and 18 may be provided with an exteriorrecess 133 disposed on the outer surface 132 at the upper end 33 of thebody 20, proximate the rod-receiving channel 29. The saddle 70preferably includes one or more wings 86, preferably positioned adjacentthe arms 73 of the saddle 70. As best shown in FIG. 17, the one or morewings 86 may have a generally T-shape and extend from the saddle 70.After the rod 101 is placed into the rod-receiving channel 29, thesaddle 70 may be lowered into the bore 22 of the body 20. As the saddle70 is lowered the one or more wings 86 are placed into engagement withthe exterior recess 133. The engagement of the one or more wings 86 withthe exterior recess 133 provides for a more integral link between thesaddle 70 and the body 20, and may thus help minimize any splaying ofthe body 20 or saddle 70.

Referring to FIGS. 19-19D, in another preferred embodiment, the body 20of the bone anchor assembly 100′ may be provided with one or more wingguides 123, one or more wide guide locks 124, one or more narrow guidelocks 141, and one or more guide stops 125. The wing guides 123 arepreferably recesses formed on the inner surface 28 of the body 20. Thewing guides 123 preferably run in the direction of the longitudinal axis32 of the bore 22. The guide locks 124, 141 are preferably openingsformed in the sides of the body 20. The guide locks 124 preferably maybe wider than guide locks 141 and are preferably positioned above thenarrow guide locks 141. Each guide stop 125 is positioned between one ofthe narrow guide locks 141 and the wide guide locks 124, separating eachguide lock 141 and guide lock 124.

Referring to FIGS. 19, 19C, the saddle 70 additionally may include wings82 to guide the saddle 70 down the bore 22 of the body 20 via the wingguides 123. The wings 82 may be protrusions of any shape or size formedon the saddle 70. The wing guides 23 may be a straight sided channel asshown in FIG. 19B or wing guides 123 can be T-shaped to interlock withthe T-shaped wings 82 shown in FIGS. 19 and 19C. The wing guides 123 onthe body 20 and the wings 82 on the saddle 70 may be configured andarranged to interlock the saddle 70 with the body. For example, the wingguides 123 and wings 82 may form a dove-tail sliding joint or T-shapedjoint to interlock the pieces. The wings 82 preferably are sized andarranged to snap into the wide guide locks 124 in the body 20.

Referring to FIGS. 19A, 19D a bushing assembly 162 is preferablyprovided in bone anchor assembly 100′. The bushing assembly 162preferably is a two-piece assembly including a bushing 160 and a sleeve183. The bushing 160 may include one or more slots 42 extending from thelower end portion 46 thereof so that at least a portion of the bushing40 is: (i) radially expandable so that the head 14 of the bone anchor 10can be inserted through the lower opening 142 in the lower end portion46 and into the interior cavity 51 of the bushing 160 and (ii) radiallycompressible to compress or lock against the head 14 of the bone anchor10 when radial forces are applied thereto. In the preferred embodiment,the slots 42 define a plurality of flexible arms 45. In anotherpreferred embodiment, a single slot 42 defining an expandable andcompressible C-type bushing element or spring-clip like element may beprovided. The bushing 160 may include a groove or recess 161 disposedproximate the upper end 47 of the bushing 160 and the sleeve 183 may bepreferably configured and arranged to fit over and snap into the recess161. The sleeve 183 preferably can rotate about longitudinal bushingassembly axis 49. The sleeve 183 preferably has a generally U-shapedchannel for receiving the spinal rod, and is constructed and arranged tofit within the bore 22. The bushing assembly 160 is preferably insertedinto axial bore 22 preferably from top opening 23 as described forbushing 60. The sleeve 183 may also preferably be provided with one ormore wings 85, preferably two wings 85, to guide the sleeve 183 down thebore 22 of the body 20 via the wing guides 123. The wings 85 may beprotrusions of any shape or size, but are preferably narrower than thewings 82 formed on the saddle 70. The wings 85 are preferably sized andarranged to slide down the narrower guide locks 141 in the body 20 andpreferably provide rotational stability to the bushing assembly 182 andthe sleeve 183. To this end, the wings 85 may be arranged to bendslightly outwards with respect to the sleeve 183 such that the wings 85may be snapped into the narrow guide locks 141. In an alternateembodiment, the sleeve 183 and the bushing 40 may be constructed as asingle, integral component.

The bushing 160 and the sleeve 183 are preferably preassembled andinstalled into the body 20 together in production. To do so, the bushing160 is inserted through the upper opening 23 of the body 20. The wings85 of the sleeve 183 may then preferably be aligned with the wing guides123 and inserted through the upper opening 23. Once the narrow wings 85are moved past the guide stops 125, the narrow wings 85 may preferablysnap into the narrow guide locks 141. In this configuration, the sleeve183 facilitates proper alignment of the bushing 160 within the body 20so that the body 20, bushing 160, and sleeve 183 subassembly may pop-onover the head 14 of the bone anchor 10. The wings 85 on the sleeve 183contained within the narrow guide locks 141 permits vertical movement ofthe sleeve 183, prevents or resists rotation of the sleeve 183 aboutaxis 32 of the body so that the U-shaped channel of the sleeve 183remains properly aligned in the body, and preferably, with guide stops125, prevents the bushing assembly 182 from detaching from the body 20.The guide stops 125 preferably also prevent the sleeve 183 from slippingback during click-on of the bone anchor head.

Once the body 20, bushing 160, and sleeve 183 are connected to the boneanchor 10, the rod 101 may be inserted into the rod-receiving channel29. The saddle 70 with wings 82 may then be installed. To do so, thewings 82 of the saddle 70 are aligned with the wing guides 123 and thesaddle 70 is moved downwards in the bore 22 of the body 20 and placedover the rod 101 and into contact with the sleeve 183. The lower portion74 of the saddle arms 73 may be configured with notched surfaces,recesses, grooves and projections so that the saddle arms 73 overlap,envelope or interlock with the top portion of the sleeve 183 to bettercontain the spinal rod 101. The engagement of the saddle arms 73 withthe sleeve 183 is preferably rotationally stable so that twisting of thesaddle 70 and body 20 is resisted. That is the connection between thesleeve 183 and saddle 70 is preferably rotationally stable. The engagingsurfaces between the sleeve 183 and the saddle 70 preferably assist orprovide the rotationally stable connection between the two parts. Thelocking cap 92, 190 may then be threadably engaged with the body 20 andmoved into a locked position. The locking of the locking cap 92, 190,urges the saddle 70 down into the sleeve 183, and hence moves thebushing assembly 162 downwards. This causes the arms 45 of the bushing160 to collapse over the head 14 of the bone anchor 10, thereby securingthe position of the bone anchor 10 with respect to the body 20.

An alternative embodiment of bushing 40 is provided in FIG. 20. The toploading bone anchor assembly 100′ of FIG. 20 includes a two-piecebushing assembly 162 having a bushing 160 to capture the head of thebone anchor and a sleeve 183′ that attaches to bushing 40 and interactswith saddle 70. Sleeve 183′ operates similar to sleeve 83 but does notinclude wings 85. In both embodiments of two-piece bushing assembly 182,the body has an enlarged chamber portion whereby the bushing isexpandable to permit the head of the bone anchor to be received withinthe cavity 51 of the bushing 160. Preferably a stop mechanism, such asfor example, guide stops 125, resist or prevent the bushing assembly 182from being detached from the body and aligns the expandable portion ofthe bushing with the enlarged portion of the chamber so that the bushingcan expand. The body also preferably would contain a chamber positionthat will compress the bushing to facilitate locking of the bone anchor.

The use of bone anchoring system 5, and in particular the use of boneanchor assembly 100, 100′ is generally as follows. First, the shaft 15of the bone anchor 10, preferably is inserted into a patient's bone,preferably the pedicle of the vertebral body 200 or the sacrum, using aninstrument such as a driver or power tool that interfaces with the drivesurface 17 at the proximal end of the bone anchor 10. A second boneanchor 10 may be implanted at a second site. As many bone anchors 10 asneeded may be implanted at any appropriate point during the course ofthe surgery. The bushing 40 preferably is positioned in the loadingposition within the lower chamber 36 of the body 20 during manufacture.In an embodiment including a bushing assembly 162, the bushing 160 andsleeve 183 may be inserted into the body 20 during manufacture. Theposition of the bushing 40, 160 preferably enables the flexible arms 45of the bushing 40, 160 to radially expand within the axial bore 22 ofthe body 20 so that the head 14 of the bone anchor 10 can be insertedthrough the lower opening 24 of the body 20 and into the interior cavity51 of the bushing 40. The body 20 with bushing 40 retained therein isthen snapped over the head 14 of the bone anchor 10 as the arms 45 ofthe bushing 40 expand to accept the head 14 of the bone anchor 10.

After the body 20 with the bushing 40, or bushing assembly 162, issnapped over the head 14 of the bone anchor 10, the body 20 may stillangulate with respect to the bone anchor. Another anchor assembly 100 ora second bone fixation element with a rod-receiving channel may beassembled at a second site to receive the rod 101. One end of the rodportion 101 may then be inserted either from the top (in the top-loadingbone anchor assembly) or the side (in the side-loading bone anchorassembly) into the rod-receiving channel 27, 29 of one of the boneanchor sub-assemblies. The locking cap 92, 190 may then be inserted intothe bore 22 of the body 20 over at least a portion of the rod 101 tocapture the rod 101.

To allow the surgeon to adjust the orientation of the anchor assemblies100, the rod portion 101 may be movably retained in the rod-receivingchannel 27, 29 of the body 20 and the bone anchor can polyaxially rotatewith respect to the body 20. To do so, the saddle 70 may be placed intothe bore 22 of the body 20 and the locking cap 92, 190 may beprovisionally or lightly threaded into the body 20 to capture to spinalrod 101. The provisional threading of the locking cap 92, 190 may causethe bushing 40 to move toward the lower chamber surfaces 37 and out ofthe loading position, thus preventing the body 20 with the bushing 40from popping off the head 14 of the bone anchor 10. The surgeon mayapply adjustments as required before locking the bone anchor 10 or rod101 into the anchor assembly 100 or locking the second anchor assembly100. Once the desired orientation of the anchor assembly 100 isachieved, the locking cap 92 or the two piece locking cap 190 may beoperated to place the bone anchor 10 and rod 101 into a locked position.The surgeon may lock the anchor assembly 100 and second anchor assembly100 in any desired sequence.

To lock the anchor assembly 100, once the rod 101 is positioned in therod receiving channel 27, 29, the threaded ring 60, 260 is tightenedcausing the threaded ring 60, 260 to move downwards in the bore 22 ofthe body 20, causing it to push down upon the saddle 70, which in turnspushes down upon the bushing 40, causing the bushing 40 to movedownwards in the lower chamber 36 of the body 20. As the bushing 40 ismoved further down relative to the body 20, the bushing 40 contacts thelower chamber surfaces 37, which apply a radial inward force to theflexible arms 45, which in turn causes the flexible arms 45 to compressagainst the head 14 of the bone anchor 10, thereby securing the positionof the bone anchor 10 with respect to the bushing 40 and hence withrespect to the body 20. The lower chamber surface 37 and the outersurface 55 of the bushing 40 preferably form a generally line contact asdescribed in International App. No. PCT/US2008/070670 the entirecontents of which are incorporated herein by reference. To secure therod 101, the setscrew 90 is tightened which moves the setscrew 90downward in the bore 22 of the body 20. The bottom surface 95 of thesetscrew 90 (FIG. 1A) pushes down on the rod 101, securing the rod 101in place.

In an embodiment utilizing a two-piece locking cap 190 the exteriorthreads 61 of the locking element 191 are placed into engagement withthe internal threads 21 of the body 20, moving the locking element 191downward in the axial bore 22 of the body 20. As the locking element 191moves downward, the locking element 191 exerts a force upon the saddle70, causing the saddle 70 to push down upon the rod 101, and/or bushing40, locking the position of the rod 101 and causing the bushing 40 tomove downwards in the lower chamber 36 of the body 20, securing theposition of the bone anchor 10 with respect to the bushing 40, andhence, with respect to the body 20, as described above. The same processmay be applied to a second anchor assembly 100, 100′ to secure the otherend of the rod 101.

If desirable, a surgeon may pop-off the body 20 from the bone anchor 10,in situ, after the anchor assembly 100 is engaged in the lockedconfiguration. Specifically, the locking cap 92, 190 of the anchorassembly 100 may be removed from the body 20 and the rod 101 may bedisengaged and extracted from the rod-receiving channel 27, 29 of theanchor assembly 100 and the second anchor assembly 100. These steps maybe executed in any desired sequence. A tool (not shown) engages thebushing 40 and the body 20 and applies a force to the bushing 40 to movethe body 20 downwardly toward the bone anchor 10. The generally linecontact between the body 20 and the bushing 40 is released and thebushing 40 is urged upward with respect to the body 20 so that thebushing 40 is in the loading position. Enough force may be applied tothe assembly to move the wings 41 up past the optional second stops 26,if provided in the body 20, so that the bushing 40 is moved to theloading/unloading position. In the loading position, the flexible arms45 can flex outwardly within the lower chamber 36 of the body 20 topermit popping-off of the body 20 and bushing 40 from the head 14 of thebone anchor 10. While the bushing 40 and body 20 may be removed from thebone anchor 10 as described, their release from the bone anchor 10preferably is non-destructive. The bushing 40 and body 20 may bereapplied to the bone anchor 10 if desired.

With reference to FIGS. 21-34, bone anchor system 5 may also preferablybe used in conjunction with a monorotational bone anchor assemblies100″, which may include bone anchors 210, 310, 410, 510, 610 rather thanpolyaxial bone anchor 10. The bone anchor 210, 310 may be preassembledin the body or a bone anchor 410, 510, 610 may be provided that permitsthe surgeon to “click-on” the body in-situ. These monorotational boneanchor assemblies generally include the locking caps 92, 190 asdescribed above for use in conjunction with bone anchor 10 and include avariation of body 20 modified to operatively associate with or connectto the various bone anchors 210, 310, 410, 510 and 610. Themonorotational bone anchor assemblies generally do not include bushing40 or bushing assembly 162. The monorotational bone anchor assembliesmay include a side loading body 20′ having a side loading channel 27, ora top loading body 20′ having a top loading rod-receiving channel 29.

With reference to FIGS. 21 and 21A, in a preferred embodiment utilizinga monorotational bone anchor, the anchor assembly 100 includes a boneanchor 210, a fastener element 240, a body 20′, and a locking cap 92,190 (not shown). The bone anchor 210 includes an upper portion 211 and alower portion 212. The upper portion 211 includes the head 214 of thebone anchor 210, a fastener engagement element 215, and one or more headengagement elements 213. Each head engagement 213 may assume the form ofa recess, protrusion or combination of both around the head 214 of thebone anchor 210 without deviating from the scope of the presentinvention. The fastener engagement element 215 is preferably a recess orgroove formed in the head 214 and is configured and arranged to receivethe fastener element 240. The fastener element 240 may be substantiallyC-shaped with an opening that is configured to receive the bone anchor210, e.g., a C-clip. The body 20 may be formed with a shoulder, groove,ledge, projection or a combination to prevent the head 214 from passingthrough the lower opening 24, and preferably engages the head 214.

To assemble the anchor assembly 100, the bone anchor 210 is placed intothe bore 22 of the body 20 through the top opening 23 or therod-receiving channel 27, 29. The lower portion 212 of the bone anchor210 exits the body 20 through the lower opening 24. The head engagementelements 213 contact the lower chamber surfaces 37 causing the head 214to be retained within the lower chamber 36. The fastener element 240 maythen be clipped onto the fastener engagement element 215 around the head214 to prevent the bone anchor 210 from moving back upwards in the bore22 of the body 20. Once the bone anchor/body subassembly is complete,the bone anchor/body subassembly may be implanted into a patient's bone.The fastener element 213 retains the bone anchor 210 in the body 20 andpermits the body 20 to rotate about vertical axis 32 so that therod-receiving channel 27, 29 can be oriented in a desirable direction. Aspinal rod 101 may then be placed into the rod receiving channel 27, 29of the body 20 and the locking cap 92, 190 engaged to secure theposition of the rod 101, and preferably the orientation of the body 20with respect to the bone anchor 210.

Referring to FIGS. 22-27, anchor assembly 100″ includes a bone anchor310 with an upper portion 311 and a lower portion 312, a fastenerelement 340, body 20, and locking cap 92, 190. The upper portion 311includes the head 314 of the bone anchor 310, a fastener engagementelement 315, and one or more head engagement elements 313. Each headengagement element 313 may assume the form of a recess, protrusion orcombination of both around the head 314 of the bone anchor 310 withoutdeviating from the scope of the present invention. The fastenerengagement element 315 may be a recess formed in the head 314, which isconstructed and arranged to receive the fastener element 340. Thefastener element 340 may be substantially ring shaped and may beprovided with one or more partial of full length slots 342 to allow thefastener element 340, e.g., a spring clip, to compress and expand sothat it can slide and lock onto fastener engagement element 315. Thebody 20 may be formed with a shoulder, groove, ledge, projection or acombination to prevent the head 314 from passing through lower opening24, and preferably engages the head 314.

To assemble the anchor assembly 100, the bone anchor 310 is placedthrough the fastener element 340 and the fastener element 340 is pushedup the bone anchor 310 (FIG. 24) until it reaches the fastenerengagement element 315, where it locks into place around the fastenerengagement element 315. The bone anchor/fastener element assembly isthen inserted into the bore 22 of the body 20 through the upper opening23 of the body 20 as shown in FIG. 25. The lower portion 312 of the boneanchor 310 exits the body 20 through the lower opening 24. The headengagement elements 313 contact the lower chamber surfaces 37 causingthe head 314 to be retained within the lower chamber 36. The fastenerelement 340 contracts to exit the bore 22 of the body 20 through thelower opening 24 and expands once the fastener element 340 has traveledbeneath the body 20 to a size (diameter) larger than lower opening 24 toprevent the bone anchor 310 from moving back up through the bore 22 ofthe body 20 (FIG. 26). Once the bone anchor/body subassembly iscomplete, the anchor/body subassembly may be implanted into a patient'sbone. After implantation of the bone anchor/body subassembly, the body20 is rotatable about the bone anchor 310 so that the orientation of therod-receiving channel 27, 29 can be adjustable by a user. A spinal rod101 may then be placed into the rod-receiving channel 27, 29 of the body20 and the locking cap 92, 190 engaged with the body 20 to capture therod 101. The locking cap 92, 190 may then be tightened to lock theposition of the spinal rod 101, and preferably the orientation of thebody with respect to the bone anchor 310 (FIG. 27).

Referring to FIGS. 28-29, in a further preferred embodiment of themonorotational bone anchor assembly, the anchor assembly 100″ includes abone anchor 410 with an upper portion 411 and a lower portion 412, afastener element 440, a body 20, and locking cap 92, 190 (not shown).The upper portion 411 includes the head 414 of the bone anchor 410, afastener engagement element 415, and one or more head engagementelements 413. Each head engagement 413 may assume the form of a recess,groove, or preferably a protrusion or projection, or a combination ofgrooves/recesses and protrusions/projections disposed around the head414 of the bone anchor 410. The fastener engagement element 415 may be arecess formed in the head 414, which is configured and arranged toreceive the fastener element 440. The fastener element 440 may besubstantially C-shaped ring with an opening 450 that is configured toexpand to clip onto the bone anchor 410 from the side, e.g., a C-clip.The fastener element 440 may include a first oblique side surface 441that is inclined and a side surface 448. The fastener element attachesto the fastener engagement element to form a protrusion on the head 414of the bone anchor 410.

To attach the fastener element 440 to the bone anchor 410 the opening450 is expanded and the clip is inserted into the recess 415. Tostabilize the fastener element 440 in the recess 415 that forms thefastener engagement element, the fastener element 440 may be distortedto friction fit the fastener element 440 in the recess 415. In oneembodiment, the fastener element 440 is twisted about axis 402 so it isdeformed so that it is slightly helically shaped so that it is frictionfit in the recess 415. It is believed that friction-fitting the fastenerelement 440 to take up or resist any free play, “slop” or movement(lateral) may reduce jamming of the fastener element 440 in the body 20.The fastener element 440 may further include an optional inclined bottomsurface 442. The body 20 is preferably provided with a recess 421 (FIG.29) on the inner surface 28 of the lower chamber 36 to receive theoblique protrusion formed by the fastener element 440 connected to thebone anchor 410.

The head 414 of the bone anchor 410 is received into the body 20, andthe protrusion formed by the fastener element 440 engages the recess 421to connect the bone anchor 410 to the body 20 and prevent the boneanchor 410 from falling out of the body 20 once the head 414 is capturedwithin the body 20. The head 414 of the bone anchor 410 is insertedthrough the lower opening 24 and the oblique surface 441 and sidesurface 448 contacts the body surrounding the lower opening 24 whichcompresses the fastener element 440 so that the fastener element 440 canpass through the opening 24. As the bone anchor 410 with fastenerelement 440 progresses up the body 20 and the side surface aligns withthe recess 421 the fastener element 440 expands into the recess 421. Ashoulder 408 on the bone anchor 410 larger than bottom opening 24prevents the bone anchor 410 from passing through the opening 24. Theexpansion of fastener element 440 and its bottom surface 442 abuttingagainst the bottom wall of the recess 421 prevents the bone anchor 410from being detached from the body 20. The recess 421 may also include anoptional inclined surface 438 to cooperate with inclined surface 442 tofurther resist the bone anchor 410 from being detached from the body 20by being pulled back out of the opening 24.

Referring to FIGS. 30-31, in another preferred embodiment of themonorotational bone anchor assembly 100″, the fastener element 540 maybe substantially ring shaped and configured to slide over the head 514of the bone anchor 510 onto the fastener engagement element 515, whichis preferably a recess disposed on the head 514 of the bone anchor 510configured to receive fastener element 540. The fastener element 540includes an oblique side surface 541 that preferably forms an obliqueprotrusion on the head 514 of the bone anchor 510 when clipped onto thefastener engagement element 515. The body 20 is preferably provided witha recess 521 (FIG. 31) on the inner surface 28 of the lower chamber 36to receive the oblique protrusion formed by the fastener element 540connected to the head 514 of the bone anchor 510. The head 514 of thebone anchor 510 is received into the body 20, and the protrusion formedby the fastener element 540 engages the recess 521 to prevent the boneanchor from falling out of the body 20 once the head 514 is clipped intoplace within the body 20.

In operation the fastener element 440 is clipped into the fastenerengagement element 415 of the bone anchor 410. Alternatively, thefastener element 540 is slid over the bone anchor 510 and onto thefastener engagement element 515. The surgeon may then implant the boneanchor 410, 510 into a patient's bone. The surgeon may then pop on thebody 20 over the head 414, 514 of the bone anchor 410, 510. The head414, 514 of the bone anchor 410, 510 is received into the body 20through the lower opening 24 and is moved up through the lower chamber36 until the fastener element 440, 540 passes the recess 421, 521 in thelower chamber 36. When the bone anchor 410, 510, and hence the head 414,514, is moved upward to engage the recess 421, 521 with the fastenerelement 440, 540, the bone anchor 410, 510 is clipped into place. Thebody 20 may still rotate with respect to the bone anchor 410, 510 sothat the rod receiving channel 27, 29 can be oriented by a user. The rod101 may then be placed into the rod-receiving channel 27, 29 of the body20 and the locking cap 92, 190 is engaged with the body 20 to secure theposition of the rod 101, and preferably the body 20 with respect to thebone anchor 410, 510.

With reference to FIGS. 32-34, in a still further preferred embodiment,the anchor assembly 100″ includes a bone anchor 610, a body 20, afastener element 640, and a locking cap (not shown). The bone anchor 610includes an upper end 611 and a lower end 612. The upper end 611includes the head 614 of the bone anchor 610, which is sized andconfigured to be received within the body 20 and may also include aflange 615 disposed on the head 614 of the bone anchor 610 forming ashoulder or ledge which will interact with the fastener element 640. Anoblique or inclined surface 609 is also formed on the head 614.

The fastener element 640 is preferably in the form of a bushing andincludes a bore 648 and a lower end portion 646 sized and configured tocapture at least a portion of the head 614 of the bone anchor 610. Thebore 648 extends from an upper opening 649 at the upper end 647 to thelower end 646 so that, for example, a drive tool, such as, for example,a screw driver, can be inserted through the fastener element 640 andinto engagement with the bone anchor 610 so that the bone anchor 610 maybe rotated into engagement with the patient's vertebra 200. The lowerend portion 646 of the fastener element 640 preferably includes aninterior cavity 651 for receiving and securing the head 614 of the boneanchor 610 to secure the position of the bone anchor 610 with respect tothe body 20. The fastener element 640 also includes one or more slots642 extending toward the lower end 646, wherein the slots 642 define aplurality of flexible arms 645.

The fastener element 640 may also include a recess 653 on its outersurface 652 formed by flanges 654 on the flexible arms 645 and a ledgeportion 655 formed on the upper portion of the fastener element 640. Thefastener element 640 is additionally sized and configured to fit withinthe lower chamber 36 of the body 20. The lower chamber surfaces 37 ofthe body 20 are preferably constructed and arranged to receive thefastener element 640 and may additionally include a protrusion 621 onthe inner surface 28 at the lower chamber 36 of the body 20 forming ashoulder 625.

The fastener element 640 is inserted from the top opening 23 or therod-receiving channel 27, 29 into the lower chamber 36 of the body sothat the ledge portion 655 of the fastener element 640 rests on theprotrusion 621 formed on the inner surface 28 of the lower chamber 36 ofthe body 20. As the fastener element 640 is inserted into the chamber36, the oblique or chamfered surface 656 of the flanges 654 of the arms645 contact the protrusion 621 and the arms 645 are compressed anddeflected inward until the flanges 654 move below the protrusion 621 atwhich time the arms 645 expand beyond the protrusion 621 so that thefastener element 640 is captured in the body 20. The ledge portion 655formed on the fastener element 640 abuts against the protrusion 621 toprevent the fastener element 640 from further downward movement in thebody 20. Below the protrusion 621 is an expanded chamber portion 636that permits the arms 645 of the fastener element 640 to expand while inthe body 20 to capture the head 614 of the bone anchor 610 as will bedescribed below.

In operation, bone anchor 610 is implanted in the patient's bone. Thefastener element 640 is prevented from falling out of the body 20through the lower opening 24 of the body 20 by the ledge portion 655engaging the protrusion 621. The fastener element 640 is also preventedfrom moving back up the bore 22 of the body 20, by flanges 654 engagingthe protrusion 621. Preferably there is a predetermined amount of freeplay to permit the fastener element 640 to move a limited longitudinaldistance within the lower chamber 36. The body/fastener elementsubassembly may then be popped over the bone anchor 610. As the boneanchor 610 is inserted into the lower opening 24 of the body 20 the boneanchor 610 moves the fastener element 640 up into the body 20 so thatthe flanges 654 of the fastener element 640 contacts and abuts againstthe protrusion 621. Continued movement of the bone anchor 610 up intothe body causes oblique surface 609 to expand the arms 645 of thefastener element 645 in the enlarged chamber portion 636 of the body sothat head 614 is received in the cavity 651 of the fastener element 640.After flange 615 of the bone anchor 610 pushes up into the cavity 651the arms 645 move inward until the surface 650 is below flange 615 ofthe bone anchor to capture the bone anchor 610 in the fastener element640.

The rod 101 may then be inserted into the rod receiving channel 27, 29and the locking cap 92, 190 engaged with the body 20 to capture the rod101 and bone anchor 610 with respect to the body 20. To lock the spinalrod and fastener element 640 with respect to the bone anchor 610, thelocking cap 92, 190 is advanced downward through the bore 22 in the body20. As the locking cap 92, 190 applies pressure to the fastener element640, the fastener element 640 advances downward or is held in the lowerchamber 36, placing the outer surface 652 of the arms 645 into contactwith the lower chamber surfaces 37 of the lower chamber 36. The lowerchamber surfaces 37 of the lower chamber 36 may be configured to exert aradial force on the arms 645, causing the arms 645 to collapse aroundthe head 614 of the bone anchor 610, thereby locking the position of thebone anchor 610 with respect to the body 20, or the lower chambersurfaces 37 may be configured to prevent the arms 645 from expanding(e.g., surfaces 37 will not exert force on arms 645 unless the arms 645expand to a larger size) in order to lock the spinal rod in the fastenerelement 640. Where a two-piece locking cap 190 is utilized, this alsosecures the position of the rod 101. Where a three-piece locking cap 92is employed, the rod 101 may be separately locked into position by thesetscrew 90, as previously described.

The fastener element 640 and body 60 may further be configured to takeup lateral movements and moments of the bone anchor relative to the bodywhich may occur during implantation as well as after implantation of thebone anchor system within the patient. In this regard, the fastenerelement 640 may optionally have one or more substantially cylindricalzones 657, 659, while the body 20 as shown in FIGS. 33 and 34 mayoptionally include one or more corresponding substantially cylindricalbands 637, 639. When the fastener element 640 is locked, the cylindricalzones 657, 659 preferably are directly opposite cylindrical bands 637,639 so that any lateral movements or moment forces are taken-up andresisted by the cylindrical zones and cylindrical bands preferablyproviding stability to the bone anchor assembly.

In the bone anchor assembly 100″ of FIG. 34, a flange 603 may optionallybe provided on the bone anchor to resist lateral moment forces that mayoccur when the bone anchor is being clicked onto the fastener element640 or the fastener element is pushed up so that the arms 645 arealigned with the enlarged chamber 636, referred to as the fastenerelement click on position. Any lateral moment applied to the bone anchor640 will cause the bone anchor to angulate in the body 20. The lateralmoment when the fastener element 640 is in the click-on position will beresisted by the cylindrical zones 657 bearing on the cylindrical band637, but since the fastener element is upward in the body bore thecylindrical zone 659 will no longer bear on the cylindrical band 639. Tobetter resist lateral moments when the fastener element 640 is in theclick-on position, bone anchor 610 may be provided with flange 603 whichoptionally has bearing surfaces 604 which will bear against cylindricalbands 639 to resist angulating of the bone anchor 640 caused by lateralmoments.

The anchor assemblies may form a single level construct, such that amultitude of anchor assemblies and/or second bone fixation elements arearranged in parallel posteriorly between a pair of vertebral bodies 200,e.g., to assist with a fusion procedure, or alternately, the bone anchorassembly may couple to a more complex construct, such as, for example, amulti-level construct. The bone anchor assembly may also coupletransversely to a complex construct, such as in serving as a trans-iliacor trans-sacral extension.

Rather than a second bone anchor assembly 100, 100′, 100″, any of theanchor assemblies 100, 100′, 100″ may be used in conjunction with a boneanchor assembly of any other type, such as a bone anchor assemblypreassembled with a bone anchor during manufacture or any other type ofanchoring assembly that is capable of receiving spinal rod 101. Thesecond bone anchor assembly can further be a monoaxial, monorotationalor a polyaxial pedicle screw assembly or can be a lamina hook with arod-receiving portion.

As will be appreciated by those skilled in the art, any or all of thecomponents described herein may be provided in sets or kits so that thesurgeon may select various combinations of components to perform a bonefixation or stability procedures and create a system which is configuredspecifically for the particular needs and anatomy of a patient. Itshould be noted that one or more of each component may be provided in akit or set. In some kits or sets, the same device may be provided indifferent shapes and/or sizes.

The anchor assembly is preferably provided to the user in a kitincluding (1) bone anchors, (2) locking caps, (3) pre-assembledbushing/body subassemblies, bushing/sleeve/body subassemblies, orfastener element/body subassemblies, and (4) spinal rods. Thepre-assembled bushing/body subassemblies, bushing/sleeve/bodysubassemblies or fastener element/body subassemblies are preferablyassembled during manufacture by inserting the bushing 40, or bushingassembly 162, or fastener element into the axial bore 22 formed in thebody 20 through the upper opening 23 formed in the body 20 until thebushing 40, bushing assembly 162 or fastener element is captured andretained in the body.

The kit is preferably delivered to the user for use preferably in spinalsurgery. During surgery, the surgeon preferably identifies a level ofthe spine where the surgery will take place, makes an incision to exposethe selected area and implants one or more bone anchors into the desiredvertebrae 200 (FIG. 3). The subassembly (body and bushing; body, bushingand sleeve; or body and fastener element) is preferably popped-on to thebone anchor by urging the head through the lower opening 24 in the body20. Accordingly, the body subassembly may be engaged with the head 14 ofthe bone anchor 10 in situ.

The anchor assembly including the bone anchor 10, 210, 310, 410, 510,610; the bushing 40 or bushing assembly 162; the body 20; and thelocking cap 92, 190 may be made from any biocompatible material now orhereafter known including, but not limited to, metals such as, forexample, titanium, titanium alloys, stainless steel, cobalt chromium,Nitinol, etc. Other materials such as, for example, composites,polymers, ceramics, and any other material now known or hereafterdiscovered may be used for the anchor assembly, its component parts, andspinal rods.

While the foregoing description and drawings represent the preferredembodiment of the present invention, it will be understood that variousadditions, modifications, combinations and/or substitutions may be madetherein without departing from the spirit and scope of the presentinvention as defined in the accompanying claims. In particular, it willbe clear to those skilled in the art that the present invention may beembodied in other specific forms, structures, arrangements, proportions,and with other elements, materials, and components, without departingfrom the spirit or essential characteristics thereof. One skilled in theart will appreciate that the invention may be used with manymodifications of structure, arrangement, proportions, materials, andcomponents and otherwise, used in the practice of the invention, whichare particularly adapted to specific environments and operativerequirements without departing from the principles of the presentinvention. In addition, features described herein may be used singularlyor in combination with other features. The presently disclosedembodiments are, therefore, to be considered in all respects asillustrative and not restrictive, the scope of the invention beingindicated by the appended claims and not limited to the foregoingdescription.

It will be appreciated by those skilled in the art that changes could bemade to the embodiments described above without departing from the broadinventive concept thereof. It is understood, therefore, that thisinvention is not limited to the particular embodiments disclosed, but itis intended to cover modifications within the spirit and scope of thepresent invention, as defined by the appended claims.

What is claimed is:
 1. An anchor assembly for use with a spinal rod forstabilizing bones or bone fragments, the anchor assembly comprising: abone anchor including an enlarged, curvate head portion; a body having alongitudinal axis, an exterior side wall, an interior wall, an upper endwith an upper opening, a lower end with a lower opening, a bore havingan interior wall, and a rod receiving channel, the bore extendingsubstantially between the upper opening and the lower opening and therod receiving channel configured and arranged to receive the spinal rod;an insert member including a first end, a second end, a lower opening,an interior cavity for receiving at least a portion of the head portionof the bone anchor, and at least one slot extending from the second end,the slot permitting the insert member to have at least a portion that isexpandable and collapsible, the insert member further having an outersurface and being movably positionable within the bore of the body; anda locking cap assembly including a saddle and a locking element, thesaddle having at least one saddle arm defining a rod receiving channel,and configured and arranged to be received within the bore of the bodyto retain the spinal rod, wherein the saddle is operatively associatedwith the locking element and the insert member, the locking elementbeing engagable with the body and movable from an unlocked position to alocked position, wherein movement of the locking element from theunlocked position to the locked position when the spinal rod is receivedin the rod-receiving channel applies pressure to the spinal rod tosecure the spinal rod with respect to the body.